This document discusses the production of formaldehyde through a catalytic vapor-phase oxidation process. It will involve designing a plant with three main units: a reactor to catalyze the oxidation of methanol and air, an absorber to absorb the formaldehyde product, and a distillation column to separate and purify streams. The target product is 50 tons per day of a 37% aqueous formaldehyde solution. The document covers relevant chemical properties, process descriptions including the silver catalyst process, and outlines the overall design problem of producing the specified amount of formaldehyde through this integrated production method.
Production of 66000 ton/year of Formaldehyde from Methanol using Silver catal...Engr Muhammad Zeeshan
Formaldehyde, the target product is an organic compound representing the most elementary configuration of the aldehydes. It behaves as a synthesis baseline for many other chemical compounds, including phenol formaldehyde, urea formaldehyde, melamine resin, Paints, and Glues. It is also used in medical field i.e. as a disinfectant and preservation of cell and tissues. The aim of this project is to reach 98% conversion of methanol using Silver Catalyst. Detailed calculations were performed in the report for all equipment in the plant including all expenses of the plant erection, taking into account the required process conditions to achieve a production capacity of 66000 ton/year of formaldehyde (as Formalin).
How to control prilling tower dust emissionPremBaboo4
Urea dust emission is the major problem for environment. In India fertilizers Produced by Prilling routs for Urea and Ammonium Nitrate. Prilling is the common process. The revamp of emission control system in prilling tower is a considerable burden. It not only presents a substantial investment but also raises the running costs and energy may increase up to 0.01 Gcal/ton of urea.. In the face of strong demand for environment friendliness and effective use of power it is then an issue of utmost importance to pick the legally emission control solution, the one that can guarantee, if not a full return on the investment, then at least cutting the cost to absolute minimum. In order to remove urea dust and ammonia, wet processes are generally applied. The available technologies vary with regard to the scrubber design, type of demisters and the gas moisturizing/spraying system. Dust emission is directly proportional to temperature. Dust emission can control by internal and external process. In India generally followed internal routs. The pollution control Board sample should be ok just thinking so. Either reduction of plant load or bypassing the recovery system at the time of sampling or manipulating data. It is the bitter truth. In reality dust emission control system should be installed in prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all urea plants. Number of Revamp Companies are available in market.
The document describes a distillation system with multiple units including a feed preheater, reboiler, distillation column, bottom product cooler, top product cooler, and condenser. It provides material and energy balances for the system, including flow rates, temperatures, heat duties, and phases of the streams at each component.
Project: Formaldehyde from methanol and airMehmoodIqbal7
1. The document describes the production of formaldehyde via the silver catalytic process. Formaldehyde is produced from methanol using a silver catalyst at high temperatures.
2. The reaction products are cooled and purified through absorption and distillation columns to separate the formaldehyde from unreacted methanol. Final products contain 37% formaldehyde solutions.
3. The silver catalytic process has advantages over alternative metal oxide processes in having lower costs, safer operations, higher yields, and more flexibility. Material and energy balances are required to design an optimal formaldehyde production process.
Production of 66000 ton/year of Formaldehyde from Methanol using Silver catal...Engr Muhammad Zeeshan
Formaldehyde, the target product is an organic compound representing the most elementary configuration of the aldehydes. It behaves as a synthesis baseline for many other chemical compounds, including phenol formaldehyde, urea formaldehyde, melamine resin, Paints, and Glues. It is also used in medical field i.e. as a disinfectant and preservation of cell and tissues. The aim of this project is to reach 98% conversion of methanol using Silver Catalyst. Detailed calculations were performed in the report for all equipment in the plant including all expenses of the plant erection, taking into account the required process conditions to achieve a production capacity of 66000 ton/year of formaldehyde (as Formalin).
How to control prilling tower dust emissionPremBaboo4
Urea dust emission is the major problem for environment. In India fertilizers Produced by Prilling routs for Urea and Ammonium Nitrate. Prilling is the common process. The revamp of emission control system in prilling tower is a considerable burden. It not only presents a substantial investment but also raises the running costs and energy may increase up to 0.01 Gcal/ton of urea.. In the face of strong demand for environment friendliness and effective use of power it is then an issue of utmost importance to pick the legally emission control solution, the one that can guarantee, if not a full return on the investment, then at least cutting the cost to absolute minimum. In order to remove urea dust and ammonia, wet processes are generally applied. The available technologies vary with regard to the scrubber design, type of demisters and the gas moisturizing/spraying system. Dust emission is directly proportional to temperature. Dust emission can control by internal and external process. In India generally followed internal routs. The pollution control Board sample should be ok just thinking so. Either reduction of plant load or bypassing the recovery system at the time of sampling or manipulating data. It is the bitter truth. In reality dust emission control system should be installed in prilling tower. It is not costly; slightly per ton of urea energy will increase but it is necessary for all urea plants. Number of Revamp Companies are available in market.
The document describes a distillation system with multiple units including a feed preheater, reboiler, distillation column, bottom product cooler, top product cooler, and condenser. It provides material and energy balances for the system, including flow rates, temperatures, heat duties, and phases of the streams at each component.
Project: Formaldehyde from methanol and airMehmoodIqbal7
1. The document describes the production of formaldehyde via the silver catalytic process. Formaldehyde is produced from methanol using a silver catalyst at high temperatures.
2. The reaction products are cooled and purified through absorption and distillation columns to separate the formaldehyde from unreacted methanol. Final products contain 37% formaldehyde solutions.
3. The silver catalytic process has advantages over alternative metal oxide processes in having lower costs, safer operations, higher yields, and more flexibility. Material and energy balances are required to design an optimal formaldehyde production process.
This document discusses prilling and granulation processes. Prilling involves spraying molten material into a prilling tower where it solidifies into spherical prills due to contact with upward air flow. Granulation converts fine particles into stronger, larger agglomerates using compression or a binding agent. The key difference is that prilling does not use a binder, produces hollow prills of varying sizes with more breakage, while granulation uses a binder to form solid, uniform size particles with less breakage and longer storage life. Granulation is commonly used in pharmaceuticals while prilling is used in fertilizer and explosive manufacturing.
The document discusses Stamicarbon's Urea 2000plus technology. It introduces the pool condenser concept, which reduced investment costs by combining equipment and simplifying the design. The pool reactor was a subsequent development that combined two process steps into one vessel, further lowering costs. Operational experience with pool condenser and reactor plants has been positive, with reliable performance and reduced maintenance needs. The technology offers significant advantages in capital cost, energy efficiency, and plant flexibility.
Hydrogen recovery from purge gas(energy saving)Prem Baboo
Ammonia is continuously condensed out of the loop and fresh synthesis gas is added. Because the synthesis gas contains small quantities of methane and argon, these impurities build up in the loop and must be continuously purged to prevent them from exceeding a certain concentration. Although this purge stream can be used to supplement reformer fuel gas, it contains valuable hydrogen which is lost from the ammonia synthesis loop In order to achieve optimum conversion in synthesis convertor, it is necessary to purge a certain quantity of gas from synthesis loop so as to as to reduce inerts concentration in the loop. Purge gas stream from ammonia process contains ammonia, hydrogen, nitrogen and other inert gases. Among them, ammonia itself is the valuable product lost with the purge stream. Moreover it has a serious adverse effect on the environment.This purge gas containing about 60% Hydrogen was fully utilised as primary reformer fuel.
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
Distillation Sequences, Complex Columns and Heat IntegrationGerard B. Hawkins
Distillation Sequences, Complex Columns and Heat Integration
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 SEQUENCING OF SIMPLE COLUMNS
4.1 Sidestream Columns
4.2 Multi-Feed Columns
5 SIMPLE COLUMN SEQUENCING AND HEAT
INTEGRATION INTERACTIONS
5.1 Energy Quantity and Quality
5.2 Heat Integration within the Total Flowsheet
6 COMPLEX COLUMN ARRANGEMENTS
6.1 Indirect Sequence with Vapor Link
6.2 Sidestream Systems
6.3 Pre-Fractionator Systems
7 COMPLEX COLUMNS AND HEAT INTEGRATION
INTERACTIONS
FIGURES
1 DIRECT AND INDIRECT SEQUENCES
2 A SINGLE SIDESTREAM COLUMN REPLACING 2
SIMPLE COLUMNS
3 A TYPICAL MULTI-FEED COLUMN
4 TYPICAL GRAND COMPOSITION CURVE
5 TYPICAL INDIRECT SEQUENCE WITH VAPOUR LINK
6 SIDESTREAM STRIPPER AND SIDESTREAM
RECTIFIER
7 SIMPLEST PRE-FRACTIONATOR SYSTEM
8 SIMPLEST PRE-FRACTIONATOR SYSTEM
9 PETLYUK COLUMN
The experiment examined pressure drop across a packed column as a function of air and water flow rates. Pressure drop increased with higher flow rates of both air and water. The relationship between log pressure drop and log air flow rate was plotted, showing they follow the same trend as theoretical predictions. Pressure drop rose sharply before a "flooding point" where liquid accumulated and filled the column.
This document provides details on the urea granulation process. It describes the characteristics of granular urea including composition requirements. It outlines the granulation process which involves spraying liquid urea solution onto seed material in a fluidized bed. Key equipment involved includes the granulator, fluid bed coolers, screens, and conveying equipment. Startup and operating procedures are also summarized, focusing on gradually heating and preparing the granulator while maintaining proper process conditions.
Brief desccription of ammonia & urea plants with revampPrem Baboo
This document provides an overview of the proposed revamp of the existing ammonia and urea plants at the Vijaipur fertilizer complex in India. The revamp aims to increase the capacity of the ammonia and urea plants through various energy saving measures. It will increase the ammonia capacity of Line I by 150 MTPD to 1750 MTPD and Line II by 225 MTPD to 1864 MTPD. The urea capacity of Line I will increase to 3030 MTPD and Line II to 3231 MTPD. A 450 MTPD carbon dioxide recovery plant will also be installed to meet the additional CO2 needs of the urea plants. The revamp aims to enhance self
Distillation is the basic and oldest chemical separation process used in the chemical industries and petroleum refining.
Let's recognize the difference between Packed and Plate columns in industry and the comparison of their usage!
Fluidization is the process of transforming fine solids into a fluid-like state using gas or liquid. It involves contacting phases in fluidized beds which allows for continuous, controlled operations and high heat and mass transfer. Fluidized beds are widely used in industrial applications like catalytic cracking, drying, and gas-solid reactions due to advantages such as good mixing and heat transfer, ease of operation, and ability to handle large quantities. However, fluidized beds can also result in particle attrition and non-uniform residence times.
The document summarizes the design of an absorption column to remove SO2 from an air stream using water. It involves selecting water as the solvent, 1.5 inch Raschig rings as the packing material, calculating the minimum water flow rate of 116,641 kg/h, determining the flooding velocity, diameter of 1.106 m, and height of 3.88 m for the packed column. The column will treat 40,000 ft3/h of air containing 20% SO2 and recover 96% of the SO2 using 30% excess water than the minimum flow rate.
This is a full course about how the Amine Sweetening Unit works, and all the factors, operations, and problems related to this unit. This course was taken from the IHRDC institute.
In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen in the ratio of approximately 3:1. Besides these components, the synthesis gas contains inert gases such as argon and methane to a limited extent. The source of H2 is demineralized water and the hydrocarbons in the natural gas. The source of N2 is the atmospheric air. The source of CO2 is the hydrocarbons in the natural gas feed. Product ammonia and CO2 is sent to urea plant. The present article intended the description of ammonia plant for natural gas based plants and the possible material balance of some section.
This technical paper discusses methods for estimating the amount of urea stored in a silo. It explains that the packing arrangement and bulk volume of urea depends on factors like inter-particle friction. It then provides three methods for calculating the urea quantity based on the shape of the urea pile: 1) for a simple conical shape, 2) for a triangular cross-section with length L, and 3) for a bottom portion parallel to the silo plus a conical top portion. The paper concludes that accurately estimating urea quantities is challenging due to non-symmetrical shapes and varying densities, but provides conceptual frameworks for making rough calculations.
This document summarizes flooding in a distillation column. Distillation separates mixtures based on differences in volatility through boiling and vaporization. Flooding occurs when excessive vapor flow carries liquid up the column, reducing efficiency. It can be detected by increases in differential pressure and decreases in separation. The document describes an experiment where a distillation column's reboiler heat was incrementally increased. Measurements from pressure transmitters showed that filtering and monitoring standard deviation of the pressure signal could provide early detection of the column approaching flooding. This allows operators to make adjustments and prevent loss of separation and reduced efficiency.
COURSE LINK:
https://www.chemicalengineeringguy.com/courses/gas-absorption-stripping/
Introduction:
Gas Absorption is one of the very first Mass Transfer Unit Operations studied in early process engineering. It is very important in several Separation Processes, as it is used extensively in the Chemical industry.
Understanding the concept behind Gas-Gas and Gas-Liquid mass transfer interaction will allow you to understand and model Absorbers, Strippers, Scrubbers, Washers, Bubblers, etc…
We will cover:
- REVIEW: Of Mass Transfer Basics required
- GAS-LIQUID interaction in the molecular level, the two-film theory
- ABSORPTION Theory
- Application of Absorption in the Industry
- Counter-current & Co-current Operation
- Several equipment to carry Gas-Liquid Operations
- Bubble, Spray, Packed and Tray Column equipments
- Solvent Selection
- Design & Operation of Packed Towers
- Pressure drop due to packings
- Solvent Selection
- Design & Operation of Tray Columns
- Single Component Absorption
- Single Component Stripping/Desorption
- Diluted and Concentrated Absorption
- Basics: Multicomponent Absorption
- Software Simulation for Absorption/Stripping Operations (ASPEN PLUS/HYSYS)
----
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More likes, sharings, suscribers: MORE VIDEOS!
-----
CONTACT ME
Chemical.Engineering.Guy@Gmail.com
www.ChemicalEngineeringGuy.com
http://facebook.com/Chemical.Engineering.Guy
You speak spanish? Visit my spanish channel -www.youtube.com/ChemEngIQA
This document describes gas sweetening processes used to remove acid gases like H2S and CO2 from natural gas. It focuses on chemical absorption processes using alkanolamine solvents like MEA, DGA, DEA, and MDEA in aqueous solutions. The general process involves absorbing acid gases from the feed gas in an absorber column, regenerating the solvent in a regenerator column, and recycling the regenerated solvent. Key unit operations discussed include the absorber, flash drum, amine/amine heat exchanger, regenerator, reboiler, and condenser. Process conditions and equipment details are provided for the typical operation of each unit.
Astm method for distillation of petroleum products at atmospheric pressureStudent
This document summarizes an experiment to determine the boiling range of kerosene using ASTM distillation. The experiment involves heating a 100mL gasoline sample in a distillation flask and measuring the temperature and volume percent distilled at intervals. A plot of the results shows the boiling range is 54-180°C. The document discusses how boiling range indicates a fuel's composition and properties, and how it affects safety, performance, and tendency to be explosive. Factors like vapor losses and condenser efficiency can impact the accuracy of the results.
The document provides design details for an acetic acid process plant with a capacity of 400,000 tonnes per year. It evaluates various process technologies for producing acetic acid and selects the methanol carbonylation process. The design includes piping and instrumentation diagrams and specifications for the main unit operations - reactor, flash tank, drying distillation column, heavy ends distillation column, absorption column, and storage tank. It also covers process control and instrumentation, safety, environmental, and economic aspects of the plant design.
This document summarizes a student's industrial project report completed at Global Heavy Chemicals Ltd. in Bangladesh. The report details the membrane cell technology process used to produce sodium hydroxide from sodium chloride. The student declares that the report fulfills the requirements for a B.Sc. in Chemical Engineering. The student thanks their supervisor and others at Global Heavy Chemicals for their guidance and support during the project.
A revolutionary new hydro-metallurgical technology has been developed by two companies; Doe Run Company, USA in partnership with M/s Engitec, Italy. A commercial plant for producing 60,000 tonnes per annum of lead metal at an estimated capital cost of 150 million US Dollar is envisaged setting up by Doe Run Company, St. Louis, Missouri, USA. The breakthrough technology not only envisages improvements in lead processing efficiencies but also is expected to drastically reduce air emissions, waste generations and water pollution and will have smaller carbon footprint.
This document discusses prilling and granulation processes. Prilling involves spraying molten material into a prilling tower where it solidifies into spherical prills due to contact with upward air flow. Granulation converts fine particles into stronger, larger agglomerates using compression or a binding agent. The key difference is that prilling does not use a binder, produces hollow prills of varying sizes with more breakage, while granulation uses a binder to form solid, uniform size particles with less breakage and longer storage life. Granulation is commonly used in pharmaceuticals while prilling is used in fertilizer and explosive manufacturing.
The document discusses Stamicarbon's Urea 2000plus technology. It introduces the pool condenser concept, which reduced investment costs by combining equipment and simplifying the design. The pool reactor was a subsequent development that combined two process steps into one vessel, further lowering costs. Operational experience with pool condenser and reactor plants has been positive, with reliable performance and reduced maintenance needs. The technology offers significant advantages in capital cost, energy efficiency, and plant flexibility.
Hydrogen recovery from purge gas(energy saving)Prem Baboo
Ammonia is continuously condensed out of the loop and fresh synthesis gas is added. Because the synthesis gas contains small quantities of methane and argon, these impurities build up in the loop and must be continuously purged to prevent them from exceeding a certain concentration. Although this purge stream can be used to supplement reformer fuel gas, it contains valuable hydrogen which is lost from the ammonia synthesis loop In order to achieve optimum conversion in synthesis convertor, it is necessary to purge a certain quantity of gas from synthesis loop so as to as to reduce inerts concentration in the loop. Purge gas stream from ammonia process contains ammonia, hydrogen, nitrogen and other inert gases. Among them, ammonia itself is the valuable product lost with the purge stream. Moreover it has a serious adverse effect on the environment.This purge gas containing about 60% Hydrogen was fully utilised as primary reformer fuel.
Amine Gas Treating Unit - Best Practices - Troubleshooting Guide Gerard B. Hawkins
Amine Gas Treating Unit Best Practices - Troubleshooting Guide for H2S/CO2 Amine Systems
Contents
Process Capabilities for gas treating process
Typical Amine Treating
Typical Amine System Improvements
Primary Equipment Overview
Inlet Gas Knockout
Absorber
Three Phase Flash Tank
Lean/Rich Heat Exchanger
Regenerator
Filtration
Amine Reclaimer
Operating Difficulties Overview
Foaming
Failure to Meet Gas Specification
Solvent Losses
Corrosion
Typical Amine System Improvements
Degradation of Amines and Alkanolamines during Sour Gas Treating
APPENDIX
Best Practices - Troubleshooting Guide
Distillation Sequences, Complex Columns and Heat IntegrationGerard B. Hawkins
Distillation Sequences, Complex Columns and Heat Integration
0 INTRODUCTION/PURPOSE
1 SCOPE
2 FIELD OF APPLICATION
3 DEFINITIONS
4 SEQUENCING OF SIMPLE COLUMNS
4.1 Sidestream Columns
4.2 Multi-Feed Columns
5 SIMPLE COLUMN SEQUENCING AND HEAT
INTEGRATION INTERACTIONS
5.1 Energy Quantity and Quality
5.2 Heat Integration within the Total Flowsheet
6 COMPLEX COLUMN ARRANGEMENTS
6.1 Indirect Sequence with Vapor Link
6.2 Sidestream Systems
6.3 Pre-Fractionator Systems
7 COMPLEX COLUMNS AND HEAT INTEGRATION
INTERACTIONS
FIGURES
1 DIRECT AND INDIRECT SEQUENCES
2 A SINGLE SIDESTREAM COLUMN REPLACING 2
SIMPLE COLUMNS
3 A TYPICAL MULTI-FEED COLUMN
4 TYPICAL GRAND COMPOSITION CURVE
5 TYPICAL INDIRECT SEQUENCE WITH VAPOUR LINK
6 SIDESTREAM STRIPPER AND SIDESTREAM
RECTIFIER
7 SIMPLEST PRE-FRACTIONATOR SYSTEM
8 SIMPLEST PRE-FRACTIONATOR SYSTEM
9 PETLYUK COLUMN
The experiment examined pressure drop across a packed column as a function of air and water flow rates. Pressure drop increased with higher flow rates of both air and water. The relationship between log pressure drop and log air flow rate was plotted, showing they follow the same trend as theoretical predictions. Pressure drop rose sharply before a "flooding point" where liquid accumulated and filled the column.
This document provides details on the urea granulation process. It describes the characteristics of granular urea including composition requirements. It outlines the granulation process which involves spraying liquid urea solution onto seed material in a fluidized bed. Key equipment involved includes the granulator, fluid bed coolers, screens, and conveying equipment. Startup and operating procedures are also summarized, focusing on gradually heating and preparing the granulator while maintaining proper process conditions.
Brief desccription of ammonia & urea plants with revampPrem Baboo
This document provides an overview of the proposed revamp of the existing ammonia and urea plants at the Vijaipur fertilizer complex in India. The revamp aims to increase the capacity of the ammonia and urea plants through various energy saving measures. It will increase the ammonia capacity of Line I by 150 MTPD to 1750 MTPD and Line II by 225 MTPD to 1864 MTPD. The urea capacity of Line I will increase to 3030 MTPD and Line II to 3231 MTPD. A 450 MTPD carbon dioxide recovery plant will also be installed to meet the additional CO2 needs of the urea plants. The revamp aims to enhance self
Distillation is the basic and oldest chemical separation process used in the chemical industries and petroleum refining.
Let's recognize the difference between Packed and Plate columns in industry and the comparison of their usage!
Fluidization is the process of transforming fine solids into a fluid-like state using gas or liquid. It involves contacting phases in fluidized beds which allows for continuous, controlled operations and high heat and mass transfer. Fluidized beds are widely used in industrial applications like catalytic cracking, drying, and gas-solid reactions due to advantages such as good mixing and heat transfer, ease of operation, and ability to handle large quantities. However, fluidized beds can also result in particle attrition and non-uniform residence times.
The document summarizes the design of an absorption column to remove SO2 from an air stream using water. It involves selecting water as the solvent, 1.5 inch Raschig rings as the packing material, calculating the minimum water flow rate of 116,641 kg/h, determining the flooding velocity, diameter of 1.106 m, and height of 3.88 m for the packed column. The column will treat 40,000 ft3/h of air containing 20% SO2 and recover 96% of the SO2 using 30% excess water than the minimum flow rate.
This is a full course about how the Amine Sweetening Unit works, and all the factors, operations, and problems related to this unit. This course was taken from the IHRDC institute.
In the plant, ammonia is produced from synthesis gas containing hydrogen and nitrogen in the ratio of approximately 3:1. Besides these components, the synthesis gas contains inert gases such as argon and methane to a limited extent. The source of H2 is demineralized water and the hydrocarbons in the natural gas. The source of N2 is the atmospheric air. The source of CO2 is the hydrocarbons in the natural gas feed. Product ammonia and CO2 is sent to urea plant. The present article intended the description of ammonia plant for natural gas based plants and the possible material balance of some section.
This technical paper discusses methods for estimating the amount of urea stored in a silo. It explains that the packing arrangement and bulk volume of urea depends on factors like inter-particle friction. It then provides three methods for calculating the urea quantity based on the shape of the urea pile: 1) for a simple conical shape, 2) for a triangular cross-section with length L, and 3) for a bottom portion parallel to the silo plus a conical top portion. The paper concludes that accurately estimating urea quantities is challenging due to non-symmetrical shapes and varying densities, but provides conceptual frameworks for making rough calculations.
This document summarizes flooding in a distillation column. Distillation separates mixtures based on differences in volatility through boiling and vaporization. Flooding occurs when excessive vapor flow carries liquid up the column, reducing efficiency. It can be detected by increases in differential pressure and decreases in separation. The document describes an experiment where a distillation column's reboiler heat was incrementally increased. Measurements from pressure transmitters showed that filtering and monitoring standard deviation of the pressure signal could provide early detection of the column approaching flooding. This allows operators to make adjustments and prevent loss of separation and reduced efficiency.
COURSE LINK:
https://www.chemicalengineeringguy.com/courses/gas-absorption-stripping/
Introduction:
Gas Absorption is one of the very first Mass Transfer Unit Operations studied in early process engineering. It is very important in several Separation Processes, as it is used extensively in the Chemical industry.
Understanding the concept behind Gas-Gas and Gas-Liquid mass transfer interaction will allow you to understand and model Absorbers, Strippers, Scrubbers, Washers, Bubblers, etc…
We will cover:
- REVIEW: Of Mass Transfer Basics required
- GAS-LIQUID interaction in the molecular level, the two-film theory
- ABSORPTION Theory
- Application of Absorption in the Industry
- Counter-current & Co-current Operation
- Several equipment to carry Gas-Liquid Operations
- Bubble, Spray, Packed and Tray Column equipments
- Solvent Selection
- Design & Operation of Packed Towers
- Pressure drop due to packings
- Solvent Selection
- Design & Operation of Tray Columns
- Single Component Absorption
- Single Component Stripping/Desorption
- Diluted and Concentrated Absorption
- Basics: Multicomponent Absorption
- Software Simulation for Absorption/Stripping Operations (ASPEN PLUS/HYSYS)
----
Please show the love! LIKE, SHARE and SUBSCRIBE!
More likes, sharings, suscribers: MORE VIDEOS!
-----
CONTACT ME
Chemical.Engineering.Guy@Gmail.com
www.ChemicalEngineeringGuy.com
http://facebook.com/Chemical.Engineering.Guy
You speak spanish? Visit my spanish channel -www.youtube.com/ChemEngIQA
This document describes gas sweetening processes used to remove acid gases like H2S and CO2 from natural gas. It focuses on chemical absorption processes using alkanolamine solvents like MEA, DGA, DEA, and MDEA in aqueous solutions. The general process involves absorbing acid gases from the feed gas in an absorber column, regenerating the solvent in a regenerator column, and recycling the regenerated solvent. Key unit operations discussed include the absorber, flash drum, amine/amine heat exchanger, regenerator, reboiler, and condenser. Process conditions and equipment details are provided for the typical operation of each unit.
Astm method for distillation of petroleum products at atmospheric pressureStudent
This document summarizes an experiment to determine the boiling range of kerosene using ASTM distillation. The experiment involves heating a 100mL gasoline sample in a distillation flask and measuring the temperature and volume percent distilled at intervals. A plot of the results shows the boiling range is 54-180°C. The document discusses how boiling range indicates a fuel's composition and properties, and how it affects safety, performance, and tendency to be explosive. Factors like vapor losses and condenser efficiency can impact the accuracy of the results.
The document provides design details for an acetic acid process plant with a capacity of 400,000 tonnes per year. It evaluates various process technologies for producing acetic acid and selects the methanol carbonylation process. The design includes piping and instrumentation diagrams and specifications for the main unit operations - reactor, flash tank, drying distillation column, heavy ends distillation column, absorption column, and storage tank. It also covers process control and instrumentation, safety, environmental, and economic aspects of the plant design.
This document summarizes a student's industrial project report completed at Global Heavy Chemicals Ltd. in Bangladesh. The report details the membrane cell technology process used to produce sodium hydroxide from sodium chloride. The student declares that the report fulfills the requirements for a B.Sc. in Chemical Engineering. The student thanks their supervisor and others at Global Heavy Chemicals for their guidance and support during the project.
A revolutionary new hydro-metallurgical technology has been developed by two companies; Doe Run Company, USA in partnership with M/s Engitec, Italy. A commercial plant for producing 60,000 tonnes per annum of lead metal at an estimated capital cost of 150 million US Dollar is envisaged setting up by Doe Run Company, St. Louis, Missouri, USA. The breakthrough technology not only envisages improvements in lead processing efficiencies but also is expected to drastically reduce air emissions, waste generations and water pollution and will have smaller carbon footprint.
PCE-Lecture-1-3-Introduction to chemical engineeringPandiaRajan52
1. The document provides an introduction to chemical engineering, including the roles of chemical engineers, unit operations and processes, and examples like combustion and nitration.
2. It describes the differences between a chemist and chemical engineer and discusses the history and development of chemical engineering as a profession.
3. The document outlines topics that will be covered, including unit operations, processes, and examples like distillation and polymerization that have important applications in chemical industries.
This document discusses applications of fluidized bed technology beyond combustion and gasification. It provides examples such as fluid catalytic cracking (FCC) for petroleum refining, reduction of iron ores, and production of melamine. FCC is described as one of the largest applications of fluidized bed technology and catalysts. The process involves cracking of hydrocarbons over a catalyst in a fluidized bed reactor and regenerator. Other examples discussed include fluidized bed applications in flue gas cleaning, production of titanium oxide, roasting of sulfide ores, and drying of coal.
PLANT DESIGN FOR MANUFACTURING OF HYDROGEN BY STEAM METHANE REFORMING (SMR)Priyam Jyoti Borah
Steam methane reforming (SMR) is one of the most promising processes for hydrogen production. Several studies have demonstrated its advantages from the economic viewpoint. Nowadays process development is based on technical and economic aspects, however, in the near future; the environmental impact will play a significant role in the design of such processes. In this paper, an SMR process is studied from the viewpoint of overall environmental impact, using an exergoenvironmental analysis. This analysis presents the combination of exergy analysis and life cycle assessment. Components, where chemical reactions occur, are the most important plant components from the exergoenvironmental point of view, because, in general, there is a high environmental impact associated with these components. This is mainly caused by the energy destruction within the components, and this in turn is mainly due to the chemical reactions. The obtained results show that the largest potential for reducing the overall environmental impact is associated with the combustion reactor, the steam reformer, the hydrogen separation unit and the major heat exchangers. The environmental impact in these components can mainly be reduced by improving their exergetic efficiency. A sensitivity analysis for some important exergoenvironmental variables is also presented in the paper.
COURSE LINK:
https://www.chemicalengineeringguy.com/courses/petrochemicals-an-overview/
Introduction:
The course is mainly about the petrochemical industry. Talks about several chemicals and their chemical routes in order to produce in mass scale the demands of the market.
Learn about:
Petorchemical Industry
Difference between Petroleum Refining vs. Petrochemical Industry
Paraffins, Olefins, Napthenes & Aromatics
Market insight (production, consumption, prices)
Two main Petrochemical Processes: Naphtha Steam Cracking and Fluid Catalytic Cracking
The most important grouping in petrochemical products
Petrochemical physical & chemical properties. Chemical structure, naming, uses, production, etc.
Basic Gases in the industry: Ammonia, Syngas, etc…
C1 Cuts: Methane, Formaldehyde, Methanol, Formic Acid, Urea, Chloromethanes etc…
C2 Cuts: Ethane, Acetylene, Ethylene, Ethylene Dichloride, Vinyl Chloride, Ethylene Oxide, Ethanolamines, Ethanol, Acetaldehyde, Acetic Acid, Ethylene Glycols (MEG, DEG, TEG)
C3 Cuts: Propane, Propylene, Propylene Oxide, Isopropanol, Acetone, Acrylonitrile, Propediene, Allyl chloride, Acrylic acid, Propionic Acid, Propionaldehyde, Propylene Glycol
C4 Cuts: Butanes, Butylenes, Butadiene, Butanols, MTBE (Methyl Tert Butyl Ethers)
C5 cuts: Isoprene, Pentanes, Piperylene, Cyclopentadiene, Dicyclopentadiene, Isoamyl, etc…
Aromatics: Benzene, Toluene, Xylenes (BTX), Cumene, Phenol, Ethyl Benzene, Styrene, Pthalic Anhydride, Nitrobenzene, Aniline, Benzoic Acid, Chlorobenzene, etc…
At the end of the course you will feel confident in how the petrochemical industry is established. You will know the most common petrochemicals as well as their distribution, production and importance in daily life. It will help in your future process simulations by knowing the common and economical chemical pathways.
IRJET- Process Simulation of High Pressure Urea Production from Carbon Dioxid...IRJET Journal
This document describes a process simulation of high pressure urea production from carbon dioxide and ammonia. The simulation was conducted using Aspen Plus software and the SRK thermodynamic model. Two stoichiometric reactors were used - the first at low temperature and high pressure for ammonium carbamate formation, and the second at elevated temperature for carbamate dehydration to urea. The simulation examined varying conversion levels of carbon dioxide and ammonium carbamate. Higher conversions led to increased urea yield, as did adding more separation stages. The study provides an improved base case process for urea synthesis that is thermodynamically feasible.
1. The document discusses treatment methods for industrial wastewater from the El Nasr Petroleum Company in Egypt, which contains high levels of phenolic compounds (naphtha) that exceed legal discharge limits.
2. Jar tests were conducted to determine the optimal doses of ferrous sulfate (Fe2+) and hydrogen peroxide (H2O2) to reduce chemical oxygen demand (COD) and remove phenols.
3. The optimum treatment conditions found were a Fe2+ dose of 0.8 g/L, H2O2 dose of 65 ml/L, pH of 9.5-10.5, and a 30 minute reaction time, which reduced COD levels from over 8,
Manufacturing of Industrial Chemicals (Acetophenone, Alcohols By Sodium Reduc...Ajjay Kumar Gupta
Growth in demand for chemicals in developing countries is high leading to substantial cross border investment in the chemical sector. In modern age chemical industries have permeated most extensively in comparison with other industries and are progressing at a very rapid pace. The chemical industry comprises the companies that produce industrial chemicals. The applications of industrial chemical are in various fields like in dyes, chemical explosives and rocket propellants, fertilizers etc.
See more: http://goo.gl/XCavLS
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The document discusses a numerical study of flow patterns, combustion, and particle transport in a cement plant calciner. It aims to investigate the effects of calciner design, heavy fuel oil viscosity, and swirl number on combustion characteristics. A computational fluid dynamics model was developed using ANSYS software to simulate the gas flow, combustion reactions, and particulate matter transport. The results provide insight into optimizing the calcination process to improve cement production efficiency and quality.
A project on the Mother plant of Petrochemical Industry.
110 MT per year production capacity of NCP plant at RIL- VMD. Detailed studies on Short residence time Furnaces, Distillation columns, Catalytic converters, heat exchangers etc. calculations made on process parameters and mechanical design aspects.
Thermal cracking is a process that breaks down heavy hydrocarbon molecules into lighter products like gasoline. It involves heating residues from crude oil distillation under pressure without a catalyst. There are different types of thermal cracking processes, including visbreaking which mildly cracks residues into fuel oil, and coking which fully converts residues into lighter products and coke. Thermal cracking is an older process that produces more olefinic and aromatic products compared to catalytic cracking.
Al AlawiApplications of hydrogen in industryHydrogen’s use in .docxsimonlbentley59018
Al Alawi
Applications of hydrogen in industry
Hydrogen’s use in industry can be divided into two main categories: (1) as a reactant in hydrogenation reactions and chemical processes, (2) as fuel and energy carrier. As a reactant, hydrogen is used to produce compounds with lower molecular weight, saturate compounds and crack heavy hydrocarbons into lighter hydrocarbons. In majority of these applications hydrogenation takes place to insert hydrogen atoms and saturate molecule or to cleave a molecule and remove heterogeneous atoms such as sulfur and nitrogen. Among the major uses of hydrogen in chemical industries, ammonia production accounts for almost 50%, petroleum processing accounts for 37%, and methanol production accounts for 8% [1-3].
In petroleum industry, hydrogen is used to react with hydrocarbons in hydroprocessing and hydrocracking processes. In hydroprocessing, hydrogen is used to hydro-genate sulfur and nitrogen compounds (for example from crude oil) and release them as hydrogen sulfide (H2S) and ammonia (NH3). In hydrocracking process, heavy hydrocarbons are cracked into lighter hydrocarbons to produce refined fuels with smaller molecules and higher H/C ratios [3].
Hydrogen is also used for production of methanol. Methanol is a feedstock for manufacturing of other chemicals and materials such as formaldehyde, plastics, plywood, paints, and textiles. In methanol production plants, hydrogen and carbon monoxide are reacted over a catalyst at a high pressure and temperature.
Other application of hydrogen in chemical and petrochemical industries include production of butyraldehyde from propylene, production of acetic acid from syngas, production of butanediol and tetrahydrofuran from maleic anhydride, production of hexamethylene diamine from adiponitrile, and production of cyclohexane from benzene.
In food industry, large amount of hydrogen is used for processing of vegetable oil and decreasing the degree of unsaturation. In this process, an increase in melting point and enhanced resistance to oxidation occur that enables preservation for a longer period of time [3, 6].
Aerospace industry is the primary consumer of fuel hydrogen. A mixture of liquid hydrogen and oxygen has been found to release the highest amount of energy per unit weight of propellant [6]. However, the cost of hydrogen liquefaction, and difficulties associated with safely store and handling it in liquid form have kept liquid hydrogen away from other fuel applications such as in automobiles [3].
Fuel hydrogen is also used in fuel cells to power electrical systems. In a fuel cell, hydrogen and oxygen from air are combined and produce electricity and water.
Production of hydrogen
Industrial processes for production of hydrogen can be divided into thermal such as hydrocarbons reforming, renewable liquid and bio-oil processing, biomass, and coal gasification; electrolytic such as water splitting; photolytic such as splitting of water by sunlight through biological a.
This document provides an overview and summary of the urea manufacturing process at Chambal Fertilizers & Chemicals Limited in India. It describes the key steps in the Snamprogetti ammonia stripping process used at the plant, including urea synthesis at high pressure, medium pressure recovery and purification, low pressure recovery and purification, urea concentration, prilling, and waste water treatment. The plant uses modern technology to produce around 2 million tons of urea per year through a continuous process involving the reaction of ammonia and carbon dioxide at high pressure and subsequent purification and recovery steps.
Thomas D. Gregory at the Michigan State University Bioeconomy Insitute, 9-14-16Kathy Walsh
Technoeconomic Analysis Applied to Chemical Processes using Renewable Feedstocks; Advanced Battery Technologies; Back to the Future: Plastics from Plants and Cars that Run on Electricity
Back to the Future: Plastics from Plants and Cars that Run on Electricity, presented by Thomas Gregory, owner/consultant for Borealis Technology Solutions at the Michigan State University Bioeconomy Institute on 10-12-16.
Simulation of hydrodesulphurization (hds) unit of kaduna refining and petroch...Alexander Decker
This document summarizes a study that simulated a hydrodesulphurization (HDS) unit of Kaduna Refining and Petrochemical Company Limited using ASPEN HYSYS software. The simulation was based on parameters like mass flow rates, temperatures and pressures obtained from the Linear Alkyl Benzene plant. The simulation involved four reactors in series to remove impurities like sulfur, nitrogen and oxygen from raw kerosene. After simulation, the treated kerosene stream showed approximately zero mole fractions of these impurities. The simulation generated data on the reaction and stripping sections that were analyzed.
EIT RM Summit 2020, September 30 [CROCODILE]Jokin Hidalgo
The CROCODILE project will showcase innovative metallurgical systems based on advanced pyro-, hydro-, bio-, iono- and electrometallurgy technologies for the recovery of cobalt and the production of cobalt metal and upstream products from a wide variety of secondary and primary European resources. CROCODILE will demonstrate the synergetic approaches and the integration of the innovative metallurgical systems within existing recovery processes of cobalt from primary and secondary sources at different locations in Europe, to enhance their efficiency, improve their economic and environmental values, and will provide a zero-waste strategy for important waste streams rich in cobalt such as batteries.
The document is a project report on the industrial production of melamine. It discusses two main processes for producing melamine - a catalyzed gas-phase production and a high pressure liquid-phase production. The report selects the high pressure liquid-phase process developed by Eurotecnica as it has advantages over other processes like not requiring a catalyst and allowing for easy integration with urea plants. It then provides details of the selected process, which involves converting molten urea to melamine at high pressure and temperature, followed by quenching, hydrolysis, crystallization and drying to produce the final product.
REMOVAL OF POLLUTANTS USING RADIAL AND VERTICAL FLOW REGIME REACTORSIAEME Publication
Batch and continuous processes were conducted to study the adsorption of methylene blue dye on to three adsorbent materials, commercial activated carbon, chemically activated corncob carbon with phosphoric acid and ion exchange resin (akualite). Batch processes were established to show the effects of solution pH, contact time, adsorbent dosage, agitation speed and initial dye concentration. Two isotherm models, Freundlich and Langmuir fitted with the experimental data found from batch processes, the Langmuir model fitted well than the Freundlich, with maximum adsorption capacities of 16.21, 30.95 and 77.52 mg/g and R2 of 0.952, 0.992 and 0.995 predicted by commercial activated carbon, corncob activated carbon akualite respectively.
Essentials of Automations: The Art of Triggers and Actions in FMESafe Software
In this second installment of our Essentials of Automations webinar series, we’ll explore the landscape of triggers and actions, guiding you through the nuances of authoring and adapting workspaces for seamless automations. Gain an understanding of the full spectrum of triggers and actions available in FME, empowering you to enhance your workspaces for efficient automation.
We’ll kick things off by showcasing the most commonly used event-based triggers, introducing you to various automation workflows like manual triggers, schedules, directory watchers, and more. Plus, see how these elements play out in real scenarios.
Whether you’re tweaking your current setup or building from the ground up, this session will arm you with the tools and insights needed to transform your FME usage into a powerhouse of productivity. Join us to discover effective strategies that simplify complex processes, enhancing your productivity and transforming your data management practices with FME. Let’s turn complexity into clarity and make your workspaces work wonders!
Unlocking Productivity: Leveraging the Potential of Copilot in Microsoft 365, a presentation by Christoforos Vlachos, Senior Solutions Manager – Modern Workplace, Uni Systems
GraphSummit Singapore | The Art of the Possible with Graph - Q2 2024Neo4j
Neha Bajwa, Vice President of Product Marketing, Neo4j
Join us as we explore breakthrough innovations enabled by interconnected data and AI. Discover firsthand how organizations use relationships in data to uncover contextual insights and solve our most pressing challenges – from optimizing supply chains, detecting fraud, and improving customer experiences to accelerating drug discoveries.
HCL Notes und Domino Lizenzkostenreduzierung in der Welt von DLAUpanagenda
Webinar Recording: https://www.panagenda.com/webinars/hcl-notes-und-domino-lizenzkostenreduzierung-in-der-welt-von-dlau/
DLAU und die Lizenzen nach dem CCB- und CCX-Modell sind für viele in der HCL-Community seit letztem Jahr ein heißes Thema. Als Notes- oder Domino-Kunde haben Sie vielleicht mit unerwartet hohen Benutzerzahlen und Lizenzgebühren zu kämpfen. Sie fragen sich vielleicht, wie diese neue Art der Lizenzierung funktioniert und welchen Nutzen sie Ihnen bringt. Vor allem wollen Sie sicherlich Ihr Budget einhalten und Kosten sparen, wo immer möglich. Das verstehen wir und wir möchten Ihnen dabei helfen!
Wir erklären Ihnen, wie Sie häufige Konfigurationsprobleme lösen können, die dazu führen können, dass mehr Benutzer gezählt werden als nötig, und wie Sie überflüssige oder ungenutzte Konten identifizieren und entfernen können, um Geld zu sparen. Es gibt auch einige Ansätze, die zu unnötigen Ausgaben führen können, z. B. wenn ein Personendokument anstelle eines Mail-Ins für geteilte Mailboxen verwendet wird. Wir zeigen Ihnen solche Fälle und deren Lösungen. Und natürlich erklären wir Ihnen das neue Lizenzmodell.
Nehmen Sie an diesem Webinar teil, bei dem HCL-Ambassador Marc Thomas und Gastredner Franz Walder Ihnen diese neue Welt näherbringen. Es vermittelt Ihnen die Tools und das Know-how, um den Überblick zu bewahren. Sie werden in der Lage sein, Ihre Kosten durch eine optimierte Domino-Konfiguration zu reduzieren und auch in Zukunft gering zu halten.
Diese Themen werden behandelt
- Reduzierung der Lizenzkosten durch Auffinden und Beheben von Fehlkonfigurationen und überflüssigen Konten
- Wie funktionieren CCB- und CCX-Lizenzen wirklich?
- Verstehen des DLAU-Tools und wie man es am besten nutzt
- Tipps für häufige Problembereiche, wie z. B. Team-Postfächer, Funktions-/Testbenutzer usw.
- Praxisbeispiele und Best Practices zum sofortigen Umsetzen
Removing Uninteresting Bytes in Software FuzzingAftab Hussain
Imagine a world where software fuzzing, the process of mutating bytes in test seeds to uncover hidden and erroneous program behaviors, becomes faster and more effective. A lot depends on the initial seeds, which can significantly dictate the trajectory of a fuzzing campaign, particularly in terms of how long it takes to uncover interesting behaviour in your code. We introduce DIAR, a technique designed to speedup fuzzing campaigns by pinpointing and eliminating those uninteresting bytes in the seeds. Picture this: instead of wasting valuable resources on meaningless mutations in large, bloated seeds, DIAR removes the unnecessary bytes, streamlining the entire process.
In this work, we equipped AFL, a popular fuzzer, with DIAR and examined two critical Linux libraries -- Libxml's xmllint, a tool for parsing xml documents, and Binutil's readelf, an essential debugging and security analysis command-line tool used to display detailed information about ELF (Executable and Linkable Format). Our preliminary results show that AFL+DIAR does not only discover new paths more quickly but also achieves higher coverage overall. This work thus showcases how starting with lean and optimized seeds can lead to faster, more comprehensive fuzzing campaigns -- and DIAR helps you find such seeds.
- These are slides of the talk given at IEEE International Conference on Software Testing Verification and Validation Workshop, ICSTW 2022.
Why You Should Replace Windows 11 with Nitrux Linux 3.5.0 for enhanced perfor...SOFTTECHHUB
The choice of an operating system plays a pivotal role in shaping our computing experience. For decades, Microsoft's Windows has dominated the market, offering a familiar and widely adopted platform for personal and professional use. However, as technological advancements continue to push the boundaries of innovation, alternative operating systems have emerged, challenging the status quo and offering users a fresh perspective on computing.
One such alternative that has garnered significant attention and acclaim is Nitrux Linux 3.5.0, a sleek, powerful, and user-friendly Linux distribution that promises to redefine the way we interact with our devices. With its focus on performance, security, and customization, Nitrux Linux presents a compelling case for those seeking to break free from the constraints of proprietary software and embrace the freedom and flexibility of open-source computing.
UiPath Test Automation using UiPath Test Suite series, part 6DianaGray10
Welcome to UiPath Test Automation using UiPath Test Suite series part 6. In this session, we will cover Test Automation with generative AI and Open AI.
UiPath Test Automation with generative AI and Open AI webinar offers an in-depth exploration of leveraging cutting-edge technologies for test automation within the UiPath platform. Attendees will delve into the integration of generative AI, a test automation solution, with Open AI advanced natural language processing capabilities.
Throughout the session, participants will discover how this synergy empowers testers to automate repetitive tasks, enhance testing accuracy, and expedite the software testing life cycle. Topics covered include the seamless integration process, practical use cases, and the benefits of harnessing AI-driven automation for UiPath testing initiatives. By attending this webinar, testers, and automation professionals can gain valuable insights into harnessing the power of AI to optimize their test automation workflows within the UiPath ecosystem, ultimately driving efficiency and quality in software development processes.
What will you get from this session?
1. Insights into integrating generative AI.
2. Understanding how this integration enhances test automation within the UiPath platform
3. Practical demonstrations
4. Exploration of real-world use cases illustrating the benefits of AI-driven test automation for UiPath
Topics covered:
What is generative AI
Test Automation with generative AI and Open AI.
UiPath integration with generative AI
Speaker:
Deepak Rai, Automation Practice Lead, Boundaryless Group and UiPath MVP
Building Production Ready Search Pipelines with Spark and MilvusZilliz
Spark is the widely used ETL tool for processing, indexing and ingesting data to serving stack for search. Milvus is the production-ready open-source vector database. In this talk we will show how to use Spark to process unstructured data to extract vector representations, and push the vectors to Milvus vector database for search serving.
Driving Business Innovation: Latest Generative AI Advancements & Success StorySafe Software
Are you ready to revolutionize how you handle data? Join us for a webinar where we’ll bring you up to speed with the latest advancements in Generative AI technology and discover how leveraging FME with tools from giants like Google Gemini, Amazon, and Microsoft OpenAI can supercharge your workflow efficiency.
During the hour, we’ll take you through:
Guest Speaker Segment with Hannah Barrington: Dive into the world of dynamic real estate marketing with Hannah, the Marketing Manager at Workspace Group. Hear firsthand how their team generates engaging descriptions for thousands of office units by integrating diverse data sources—from PDF floorplans to web pages—using FME transformers, like OpenAIVisionConnector and AnthropicVisionConnector. This use case will show you how GenAI can streamline content creation for marketing across the board.
Ollama Use Case: Learn how Scenario Specialist Dmitri Bagh has utilized Ollama within FME to input data, create custom models, and enhance security protocols. This segment will include demos to illustrate the full capabilities of FME in AI-driven processes.
Custom AI Models: Discover how to leverage FME to build personalized AI models using your data. Whether it’s populating a model with local data for added security or integrating public AI tools, find out how FME facilitates a versatile and secure approach to AI.
We’ll wrap up with a live Q&A session where you can engage with our experts on your specific use cases, and learn more about optimizing your data workflows with AI.
This webinar is ideal for professionals seeking to harness the power of AI within their data management systems while ensuring high levels of customization and security. Whether you're a novice or an expert, gain actionable insights and strategies to elevate your data processes. Join us to see how FME and AI can revolutionize how you work with data!
Threats to mobile devices are more prevalent and increasing in scope and complexity. Users of mobile devices desire to take full advantage of the features
available on those devices, but many of the features provide convenience and capability but sacrifice security. This best practices guide outlines steps the users can take to better protect personal devices and information.
Unlock the Future of Search with MongoDB Atlas_ Vector Search Unleashed.pdfMalak Abu Hammad
Discover how MongoDB Atlas and vector search technology can revolutionize your application's search capabilities. This comprehensive presentation covers:
* What is Vector Search?
* Importance and benefits of vector search
* Practical use cases across various industries
* Step-by-step implementation guide
* Live demos with code snippets
* Enhancing LLM capabilities with vector search
* Best practices and optimization strategies
Perfect for developers, AI enthusiasts, and tech leaders. Learn how to leverage MongoDB Atlas to deliver highly relevant, context-aware search results, transforming your data retrieval process. Stay ahead in tech innovation and maximize the potential of your applications.
#MongoDB #VectorSearch #AI #SemanticSearch #TechInnovation #DataScience #LLM #MachineLearning #SearchTechnology
Pushing the limits of ePRTC: 100ns holdover for 100 daysAdtran
At WSTS 2024, Alon Stern explored the topic of parametric holdover and explained how recent research findings can be implemented in real-world PNT networks to achieve 100 nanoseconds of accuracy for up to 100 days.
Climate Impact of Software Testing at Nordic Testing DaysKari Kakkonen
My slides at Nordic Testing Days 6.6.2024
Climate impact / sustainability of software testing discussed on the talk. ICT and testing must carry their part of global responsibility to help with the climat warming. We can minimize the carbon footprint but we can also have a carbon handprint, a positive impact on the climate. Quality characteristics can be added with sustainability, and then measured continuously. Test environments can be used less, and in smaller scale and on demand. Test techniques can be used in optimizing or minimizing number of tests. Test automation can be used to speed up testing.
Maruthi Prithivirajan, Head of ASEAN & IN Solution Architecture, Neo4j
Get an inside look at the latest Neo4j innovations that enable relationship-driven intelligence at scale. Learn more about the newest cloud integrations and product enhancements that make Neo4j an essential choice for developers building apps with interconnected data and generative AI.
Let's Integrate MuleSoft RPA, COMPOSER, APM with AWS IDP along with Slackshyamraj55
Discover the seamless integration of RPA (Robotic Process Automation), COMPOSER, and APM with AWS IDP enhanced with Slack notifications. Explore how these technologies converge to streamline workflows, optimize performance, and ensure secure access, all while leveraging the power of AWS IDP and real-time communication via Slack notifications.
Communications Mining Series - Zero to Hero - Session 1DianaGray10
This session provides introduction to UiPath Communication Mining, importance and platform overview. You will acquire a good understand of the phases in Communication Mining as we go over the platform with you. Topics covered:
• Communication Mining Overview
• Why is it important?
• How can it help today’s business and the benefits
• Phases in Communication Mining
• Demo on Platform overview
• Q/A
Communications Mining Series - Zero to Hero - Session 1
4. properties of_formaldehyde
1. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 1
CONTENTS
1. Acknowledgement
2. Summary
3. Introduction
4. Properties of Formaldehyde
Physical properties
Chemical properties
Method of analysis
5. Manufacturers and economics
6. Usage and applications
7. Different processes for the manufacture of Formaldehyde
Silver Catalyst process
Oxide process
Reason for choosing silver process
8. The Silver process
Process description
Controlling Parameters
Equipment description
Stream description
9. Material Balance
General information
Material balance around different equipments
Overall material balance
10.Energy Balance
Air preheater
Energy balance around methanol before evaporation
Methanol Evaporator.
Reactor effluent gases cooling
2. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 2
11.Process design
Reactor
Absorption Column
Process design of few other equipments
12.Mechanical Design
Reactor
Absorption Column
13.Process utilities
14.Control and Instrumentation
15.Plant Safety
16.Effluent Treatment
Design of Deionizer
17.Plant location and layout
Plant location
Plant layout
18.Plant Economics
19.Bibliography
20.Bibliography
21.Nomenclature
3. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 3
ACKNOWLEDGEMENT
This project is the result of the continuous guidance and encouragement of the
teachers of The Department of Chemical Engineering and Technology, IIT-BHU.
I express my deep sense of gratitude and reverence to Prof. A.S.K. Sinha, Head of
Department, Department of Chemical Engineering and Prof. P. Ahuja, Prof. KK
Singh, Dr. VL Yadav and Dr. Pradeep Kumar, Project Coordinators, for providing
us the opportunity to work in this project, for their scrupulous supervision and
being available for us to sort out any kind of trouble in the way.
It is my privilege to express indebtedness and deep sense of gratitude to all the
respected teachers of our department for their guidance throughout the duration
of the project. I also extend my gratitude to the library staff for their co-
operation.
Finally, I would like to thank all my batch-mates for their unalloyed helping hands
which provided us with both material and moral support throughout the project.
Date: _____________ _______________
Shivam Singh
10102EN067
B.Tech. Part-IV
4. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 4
SUMMARY OF THE PROJECT
The main objective of this project is to conduct a comprehensive study, from a
chemical point of view, that would ultimately lead to an integrated design of a
plant that produces 50 TDP of Formaldehyde.
During this study we will consider many aspects including the entire plant‟s process
unit design, process flow diagrams, cost estimations, operation parameters,
equipment sizing, construction materials and environment/safety precautions.
This project requires the theoretical and practical application of mass transfer,
heat transfer, fluid dynamics, unit operations, reaction kinetics and process
control. There are several tasks that are crucial to the completion of the project
outlines including mass and energy balances, design of the reactor, design of heat
exchangers, design of the absorber and distillation column, energy optimization,
economic analysis and hazard analysis.
Formaldehyde (CH2O), the target product of the project‟s plant, is an organic
compound representing the simplest form of the aldehydes. It acts as a synthesis
baseline for many other chemical compounds including phenol formaldehyde, urea
formaldehyde and melamine resin. The most widely produced grade is formalin (37
wt. % formaldehyde in water) aqueous solution.
In this project‟s study, formaldehyde is to be produced through a catalytic vapour-
phase oxidation reaction involving methanol and oxygen according to the following
reactions:
CH3OH + 1/2O2 → HCHO + H2O (1)
CH3OH → HCHO +H2 (2)
First reaction is desirable which is exothermic with a selectivity of 9, while the
second is an endothermic reaction. The project‟s target is to design a plant with a
capacity of 50Tons/day. This plant is to include three major units; a reactor, an
absorber and a distillation column. Also it includes pumps, compressors and heat
exchangers. All are to be designed and operated according to this production
capacity.
5. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 5
PROBLEM INFORMATION
Formaldehyde is to be commercially manufactured on an industrial scale from
methanol and air in the presence of a sliver catalyst or the use of a metal oxide
catalyst. The former of these two gives a complete reaction of oxygen. However
the second type of catalyst achieves almost complete methanol conversion. The
silver catalyzed reactions are operated at atmospheric pressure and very high
temperatures (600o
C – 650o
C) presented by the two simultaneous reactions above
(1) and (2).
The standard enthalpies of these two reactions are ΔHo
1 = -156 KJ and ΔHo
2 = 85
KJ respectively. The first exothermic reaction produces around 50 % -- 60 % of the
total formed formaldehyde. The rest is formed by the second endothermic
reaction.
These reactions are usually accompanied by some undesired by-products such as
Carbon Monoxide (CO), Carbon Dioxide (CO2), Methyl Formate (C2H4O2) and Formic
Acid (CH2O2). Below is table of these side reactions that may take place in the
process:
6. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 6
The reactor in this project‟s problem is to receive two streams; the first is a
mixture of fresh methanol and recycled methanol. The second stream to the
reactor mixed with the first is compressed fresh air.
The absorber receives the reactor‟s outlet and afresh stream of water. Absorption
of 99% is expected. The distillation column receives the liquid then separates the
overhead methanol stream then recycles it back to methanol fresh feed mixing
point.
The bottom formaldehyde stream is pumped and mixed with deionized water
forming (37 wt. % formaldehyde) formalin stream which sent for storage. The
mixing is presented as follows:
The catalyst to be implemented in the reactor‟s design is silver wired gauze layers
or catalyst bed of silver crystals. The catalyst is spherical with 1mm diameter and
a void fraction or porosity of 0.5. The common design of the silver catalyst is a thin
shallow catalyzing bed with a thickness of 10 to 55 mm.
The usual life span of this catalyst is three to eight months, where the silver can
be recovered. The purity of the feed flow rates is very crucial due to the fact that
the catalyst is very receptive to poisoning that would kill the reaction and reduces
the production to zero if traces of sulfur or a transition metal are present.
7. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 7
PHYSICAL & CHEMICAL PROPERTIES
This section includes all the major participating materials to the production plant.
These properties are based upon operating conditions of the plant‟s design:
INITIAL BLOCK FLOW DIAGRAM
8. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 8
LITERATURE REVIEW OF PRODUCTION PROCESS
Formaldehyde was discovered in 1859 by a Russian chemist named Aleksandr
Butlerov. Then in 1869, it was ultimately identified by the German chemist August
Hofmann. The manufacture of formaldehyde started in the beginnings of the
twentieth century. Between 1958 and 1968, the annual growth rate for
formaldehyde production averaged to 11.7%.
In the mid-1970s, the production was 54% of capacity. Annual growth rate of
formaldehyde was 2.7% per year from 1988 to 1997. In 1992, formaldehyde ranked
22nd among the top 50 chemicals produced in the United States. The total annual
formaldehyde capacity in 1998 was estimated by 11.3 billion pounds. Since then
and the production capacity around the globe is expanding exponentially reaching
a world‟s production of 32.5 million metric tons by 2012.
Due to its relatively low costs compared to other materials, and its receptivity for
reaching high purities, formaldehyde is considered one of the most widely
demanded and manufactured materials in the world. It is also the centre of many
chemical researches and alternative manufacture methods.
This also explains the vast number of applications of this material including a
building block for other organic compounds. Formaldehyde is a very versatile
chemical and it is used in many industries, including -
Antiseptic, Germicide and Fungicide
Purifier in Sugar Industry
Leather Tanning
Photograph Washing
Wood Working
Cabinet Making Industries
Glues and Adhesives
Paints
Explosives
Tissue Preservation
One of the main use of Formaldehyde is formaldehyde based resins. Most of the
formaldehyde produced in the world is used for this. Different resins are made
from formaldehyde using different substrates. One of the most popular is Urea-
Formaldehyde resin. Its major use is as adhesives and it is also used as a binder for
glass fibre roofing materials. We will now discuss the various productions methods
available.
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DIFFERENT PROCESSES FOR MANUFACTURE
In general two types of processes are used today.
THE SILVER CATALYST PROCESS
This process is based on partial oxidation and reduction process at 600 °C on silver
grains, works with the excess of methanol above the upper explosion limit of the
mixture methanol-air.
In this process, formaldehyde is formed both by oxidation and by dehydrogenation
reactions:
CH3OH + 1/2O2 → HCHO + H2O + 37 KCal/g-mol
CH3OH → HCHO+H -20.3 KCal/g-mol
.
The other minor reactions that are taking place are:
CH3OH+ O2 → CO + 2 H2O -162 KCal/g-mol
H2 + ½ O2 → H2O -241.82 KJ/g-mol
HCHO+ ½ O2 → CO + H2O -563.46 KJ/g-mol
HCHO → CO + H2
The reaction occurs over a silver catalyst at typical conditions of (560-
620o
C) and pressure slightly over atmosphere. Methanol conversion is 65- 75
% per pass.
THE OXIDE PROCESS
This process is based on the air oxidation of the methanol under “Lean”, i.e. low
methanol concentration, conditions to avoid the explosive range.
In this process the methanol is produced only by the oxidation reaction:
CH3OH + 1/2O2 → HCHO + H2O + 37 KCal/g-mol
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A small portion of formaldehyde gets oxidized further:
HCHO+1/2O2 → CO + H2O -563.46 KJ/g-mol
The reactions occur over a mixed oxide catalyst containing molybdenum oxide and
iron oxide in the ratio 1.5 to 3. The reaction temperature is around 550o
F and the
reaction is slightly over atmospheric pressure. An excess air is used to ensure a
near complete and to avoid the explosive range for methanol.
Fresh methanol is mixed with air plus recycled gas in a steam-heated vaporizer.
The effluent from this device is fed to the reactor, which is of the vertical packed-
tubular type. The reacting gas mixture flows downward through the tubes and
transfers its heat of reaction to a circulating heat transfer medium on the shell
side of the reactor.
The heat transfer medium in turn vaporizes the feed water to produce steam at
pressures up to about 25 atmosphere .The catalyst is granular or spherical
supported Fe/Mo and has aging characteristics such that over the period of its life
(12-15 months) the bed temperature must be increased from about 450 – 550 o
F.
The exit gases from the reactor pass through a heat recovery exchanger, where
low pressure steam is generated, and thence to the absorption column where
water is used as the scrubber column.
The absorber can be either of the packed or the tray type. The top of the absorber
is kept at a low temperature in order to ensure adequate removal of formaldehyde
from the overhead gases. The bottom stream from the absorber represents the
final product. Because the reaction conditions promote more formic acid than do
those for the silver process, it is necessary to remove this acid by ion exchange
method.
A large portion of the absorber overhead is recycled back to the feed system. This
permits the methanol content of the reactor feed to be as high as 9.0 volume%
and causes a dilution of the gas from the absorber to the point that is not always
necessary to provide further treatment of the gas discharged from the system. For
this reason, the absorption column in this process is higher than that foe silver
catalyst process.
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REASON FOR CHOOSING SILVER CATALYST PROCESS
Studies of the two processes based on the nominal size of 100,000,000 lb/yr of 37%
formaldehyde solution showed that the silver process was far economical than the
oxide process. It was found that the capital cost of the silver process was about
20% lower than the oxide process with manufacturing cost essentially the same.
The conversion of methanol to formaldehyde in the improved silver process is
normally between 77% and 95%, while in the older it is about 55%. So, conversion is
also not a problem anymore.
The most radical improvements in the silver catalyst process have been made by
BASF and are now used commercially. A different form of the catalyst, a higher
reaction temperature, and changes in reactor feed composition have made
possible a high methanol conversion; thus, it is no longer necessary to recover
unreacted methanol. Maximum size of a production unit has also been increased by
these changes.
PROCESS DESCRIPTION OF SILVER CATALYST PROCESS
This process is based on partial oxidation and reduction process at 600 °C on silver
grains, works with the excess of methanol above the upper explosion limit of the
mixture methanol-air.
In this process, formaldehyde is formed both by oxidation and by dehydrogenation
reactions:
CH3OH + 1/2O2 → HCHO + H2O + 37 KCal/g-mol
CH3OH → HCHO + H2 -20.3 KCal/g-mol
The other minor reactions that are taking place are:
CH3OH + O2 → CO + 2 H2O -162 KCal/g-mol
H2 + ½ O2 → H2O -241.82 KJ/g-mol
HCHO+ ½ O2 → CO + H2O -563.46 KJ/g-mol
HCHO → CO + H2
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The reaction occurs over a silver catalyst at typical conditions of (560-620o
C) and
pressure slightly over atmosphere. Methanol conversion is 65- 75 % per pass. Since
the reactor feed is kept on the rich side of the explosive limit, all the oxygen is
converted .Unreacted methanol is separated from the reaction mixture and
recycled.
A flow diagram is shown. Fresh Methanol, which must be free from iron carbonyls
and sulphur compounds (catalyst poison), is combined with recycle methanol and
pumped through a steam-heated vaporizer. An additional heat exchanger for super
heating the methanol may also be used. Air is drawn through a filter and
compressed in a blower for feed to the process. An air washer is provided for
removal of possible catalyst poisons, and while water is usually sufficient for the
scrubbing liquid, caustic solutions are sometimes needed. The washed air is pre
heated and mixed with fresh feed methanol to give a combined feed temp. of
about 150o
C. Provision is made for the addition of up to 0.75 lb steam /lb
methanol to serve as thermal ballast for reaction control.
The converter consists of a feed distribution chamber, a shallow bed of catalyst,
and a waste heat boiler. The catalyst is in the form of silver crystals or gauge and
the catalyst bed typically is 0.5-1.0 in deep and up to 6-7 ft. in diameter. To avoid
undesirable reactions it is necessary to quench the reaction product in less than
about 0.02 s.
Quenching is accomplished in a directly connected shell-and-tube heat exchanger
where the net exothermic heat of reaction is used to generate steam. Typically
the catalyst is contained in a basket resting on top of the waste heat boiler upper
tube sheet, and the gases flow downward through the tubes. These gases then pass
to the absorber where formaldehyde and methanol are recovered from bottom
liquid.
The absorber typically comprises two absorption/cooling sections with
recirculating liquid (thus providing a maximum of two theoretical stages). Either
packing or trays can be used for the absorber column. the heat of solution and the
residual sensible heat in the gases is removed by heat exchangers. Uncondensed
material from the circulating sections flows upward through a water contracting
zone for further absorption and finally leaves the top of the column and flows to a
suitable device for removing residual organics and carbon monoxide. Since the
gases have heating value, it is usually appropriate to add it to the fuel used for
steam generation boilers.
The absorber bottoms stream is pumped to the still where methanol is separated
overhead and the product formaldehyde solution is the bottom stream. The water
content of the bottoms is controlled by the amount of makeup water added at the
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top of the absorption column, and thuds there are definite upper limit for the
water content in the bottoms.
The methanol still typically is a tray column with conventional refluxing and re-
boiling. For reduction of the bottom to 1.0 wt% methanol, 40 bubble cap trays are
used. Residence time distribution can depend on the shifting equilibrium
composition of the liquid, and the controlled residence time characteristics of the
bubble cap tray appear advantageous. The methanol net distillate is recycled back
to the fresh feed of methanol. The recycle is done in vapor phase to conserve
energy. Also, some design employs vacuum distillation of methanol still to
discourage the formation of higher products like acetaldehyde.
If the formic acid content is higher then the distillate bottom is passed through
deionizer. Also a certain amount of product is left in distillation column for
stabilization.
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LIST OF EQUIPMENTS
The production plant contains following equipment –
One (1) evaporator
One (1) air blowers (one with speed variator)
One (1) reactor with boiler tubes
One (1) gas/gas heat exchanger
Seven (7) liquid/liquid heat exchangers
One (1) condensers
One (1) packing absorption column
Two (2) tray absorption columns (bubble caps)
One (1) tray distillation column (bubble caps)
Vessels
Pumps (Sihi) doubled to secure the process
Pipes, valves, etc.
Steel : SS 316 L
Protection of electric motors : IP 55 Eexd II BT 4
CONTROLLING PARAMETERS:
1. Composition of the feed entering the evaporator: It is controlled by means
of automatic valves that control the inflow rate of methanol & water. The
composition is kept maintained at 64% methanol as it is crucial in deciding
the composition of the feed entering the reactor.
2. Temperature of the evaporator. It is kept around 70-72C by controlling the
rate of steam applied in the outer jacket. A temperature gage on the
evaporator indicates temperature continuously. It is important as it decides
the amount of methanol evaporating & thus the composition of the feed to
the reactor.
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3. Pressure of the evaporator. Maintained at ~ 900 mm wc & monitored by
means of pressure gage.
4. Level of the mixture in the evaporator. Maintained at 45% of total capacity
& monitored by a level indicator outside the evaporator. It is important as it
decides the rate of evaporation of the mixture & thus affects the yield.
5. Composition of the feed entering the reactor. Maintained at 80% methanol &
controlled indirectly by controlling the composition of the feed entering the
evaporator. It is important as it controls the composition of formaldehyde
formed.
6. Phase of the feed entering the reactor. No liquid should enter the reactor
dome as it could spoil the silver bed. To ensure this feed is passed through
superheater before it enters the reactor so that no condensation takes
place. In addition to this another separator is employed just before the feed
enters the reactor which filters out any liquid & send it back to the
evaporator.
7. Temperature & pressure inside the reactor. The temperature should be
maintained at 680-700C. This is important as the reaction conditions affect
the yield.
8. Composition of the formaldehyde leaving the absorption column. It is
maintained at 37% formaldehyde by means of controlling the flow rate of
the D.M. water added from the top of absorption column.
9. Other gases present should be removed.
10. Specific gravity of formaldehyde :The specific gravity of formaldehyde is
1.12.
INFLUENCE OF REACTION TEMPERATURE
Conversions and yields vary as a function of temperature. A light-off temperature
was observed at about 570 K. CO2 displayed a maximal yield at the relatively low
temperature of 575 K and then dropped off with temperature. The yield of
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formaldehyde increased gradually with temperature and reached a maximum at
about 923 K, which corresponds well with the commercial operation temperature.
The abrupt decrease of the formaldehyde yield above 923 K was accompanied by a
yield increase of CO and H2, suggesting a gas phase decomposition of formaldehyde
to CO and H2 at the high temperature. Formic acid appeared only in a limited
temperature region (approximately 570–850 K) and could not be observed in the
high temperature region before the deactivation of catalyst
INFLUENCE OF RESIDENCE TIME
Methanol conversion and the selectivity to formaldehyde and hydrogen were
determined at different residence times (0.06–0.45 s). The higher the residence
time was, the more methanol was converted.
However, the longer residence time was not beneficial for the formaldehyde
formation: its selectivity decreased apparently under the longer residence time,
which may be partly due to the fast decomposition of formaldehyde in the gas
phase to H2 and CO at high operation temperatures. The H2 selectivity did increase
with residence time, albeit not to the extent that the formaldehyde selectivity
decreased.
INFLUENCE OF MOLAR RATIO OF H2O / CH3OH IN THE FEED
The influence of water vapor in the reaction gas on the formaldehyde selectivity
was estimated. Water vapor content was varied in the region of H2O/CH3OH molar
ratio of 0–2.0. The space velocity was kept constant by varying the N2 flow
accordingly. This led to a constant CH3OH/O2 molar ratio. Each result was an
average over a 15 h lasting stationary test.
The conversion of methanol increased with the H2O/CH3OH molar ratio, however,
the selectivity to formaldehyde passed through a maximum around a H2O/CH3OH
molar ratio of about 0.75, which corresponds basically well with the above-
mentioned molar ratio of 0.67 in industrial formaldehyde manufacture (indicated
by the vertical dashed line). Because of the experimental error in the
formaldehyde detection, the experiment was reproduced at different feed
concentrations, supporting the conclusions reported above.
It is also show that the selectivity to CO2 decreased with the molar ratio of
H2O/CH3OH. The more water vapor was fed in the reaction gas, the less CO2 was
detected.
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SAFETY & ENVIRONMENT PRECAUTIONS
The main concern is mainly with precautions and protocols that are to be followed
while handling materials in the plant. Safety equipment includes: splash goggles,
protective coats, gloves and safety shoes are all required in dealing with these
materials regardless of the their reactivity and stability. These documentations
will include the two target materials and compounds encountered and utilized in
the plant as follows:
METHANOL
It‟s a light, volatile, colorless, clear and flammable liquid. It has a
distinctive sweetish smell and close to alcohol in odor and colorlessness.
Methanol is very toxic to humans if ingested. Permanent blindness is caused
if as little as 10 mL of methanol is received and 30 mL could cause death.
Even slight contact with the skin causes irritation.
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EXPOSORE
Exposure to methanol can be treated fast and efficiently. If the contact was
to the eyes or skin, flushing with water for 15 minutes would be the first
course of action. Contaminated clothing or shoes are to be removed
immediately. If the contact is much more series, use disinfectant soap, then
the contaminated skin is covered in anti-bacteria cream. Inhalation of
methanol is much more hazardous than mere contact. If breathing is
difficult, oxygen is given, if not breathing at all artificial respiration
REACTIVITY
Methanol has an explosive nature in its vapor form when in contact with
heat of fires. In the case of a fire, small ones are put out with chemical
powder only. Large fires are extinguished with alcohol foam. Due to its low
flash point, it forms an explosive mixture with air. Reaction of methanol and
Chloroform + sodium methoxide and diethyl zinc creates an explosive
mixture. It boils violently and explodes.
STORAGE
The material should be stored in cooled well-ventilated isolated areas. All
sources of ignition are to be avoided in storage areas.
FORMALIN( FORMALDEHYDE 37 WT% SOLUTION)
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This material is a highly toxic material that the ingestion of 30 ml is
reported to cause fatal accidents to adult victims. Formaldehyde ranges
from being toxic, allergenic, and carcinogenic. The occupational exposure
to formaldehyde has side effects that are dependent upon the composition
and the phase of the material. These side effects range from headaches,
watery eyes, sore throat, difficulty in breathing, poisoning and in some
extreme cases cancerous. According to the International Agency for
Research on Cancer (IARC) and the US National Toxicology Program: „‟known
to be a human carcinogen‟‟, in the case of pure formaldehyde.
FIRE HAZARDS
Formaldehyde is flammable in the presence of sparks or open flames.
EXPOSURE
Exposure to methanol can be treated fast and efficiently. If the contact was
to the eyes or skin, flushing with water for 15 minutes would be the first
course of action. If the contact is much more series, use disinfectant soap,
then the contaminated skin is covered in anti-bacteria cream. Inhalation of
methanol is much more hazardous than mere contact. The inhalator should
be taken to a fresh air.
STORAGE AND HALDLING
Pure Formaldehyde is not stable, and concentrations of other materials
increase over time including formic acid and para formaldehyde solids. The
formic acid builds in the pure compound at a rate of 15.5 – 3 ppm/d at 30
oC, and at rate of 10 – 20 ppm/d at 65 oC. Formaldehyde is best stored at
lower temperatures to decrease the contamination levels that could affect
the product‟s quality. Stabilizers for formaldehyde product include
hydroxypropylmethylcellulose, Methyl cellulose, ethyl cellulose, and poly
(vinyl alcohols).
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MATERIAL BALANCE
In this section, material balance over some important units has been performed
manually. The final stream tables give the composition in all streams.
Equation used
Inlet – outlet + generation – consumption = accumulation
as accumulation = 0
equation given above can be applied for mass balance.
MASS BALANCE FOR REACTOR:
Main reactions in reactor are -
CH3 OH + ½ O2 = HCHO + H2O ……….(1)
CH3 OH = HCHO + H2 ……….(2)
CH3 OH + O2 = CO + 2H2O ……….(3)
ASSUMPTIONS
Total molar conversion of methanol is 81%.
60% of formaldehyde is formed via reaction 1 and remainder is formed
by reaction 2.
Conversion values for reaction 1 and 2 are obtained by using literature
survey on the formaldehyde production process.
Formaldehyde produced = 50 TPD
= (50*1000)/30 = 1666.66 Kmol/day
= 69.44 Kmol/hr (approx. 70 Kmol/hr)
From reaction 1, formaldehyde produced = (0.6*70) Kmol/hr = 42 Kmol/hr
From reaction 2, formaldehyde produced = (0.4*70) Kmol/hr = 28 Kmol/hr
By stoichiometry, kmols of methanol converted = 42+28= 70 Kmol/hr
Now, 1% of methanol total is consumed in reaction 3.
So, total methanol taken in feed stream = (70*100)/80 = 87.5 Kmol/hr
Since,the ratio of methanol to oxygen for this process in industrial reactors is 2.5.
Amount of oxygen required = 87.5/2.5 = 35 Kmol/hr
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Hence,nitrogen in feed stream = 140 Kmol/hr
Amount of methanol consumed in reaction 3 = 87.5/100 = 0.875 Kmol/hr
Total amount of water produced in reaction 1&3 = (2*0.875)+42 = 43.75 Kmol/hr
Hydrogen in exit stream = 28 Kmol/hr
Carbon monoxide in exit stream = 0.875 Kmol/hr
Amount of oxygen consumed in reaction 1&3 = (0.5*42)+0.875 = 21.875 Kmol/hr
Oxygen remaining = 35-21.875 = 13.125 Kmol/hr
Unreacted methanol = 87.5-70-.875 = 16.625 Kmol/hr
REACTOR
Components Stream 9
(kmol/hr)
Stream 10
(kmol/hr)
Methanol 87.5 16.625
Formaldehyde - 70
Water - 43.75
Oxygen 35 13.125
Nitrogen 140 140
Hydrogen - 28
Carbon monoxide - 0.875
MASS BALANCE FOR ABSORBER:
As more than 90% formaldehyde is absorbed in absorption column
In inlet stream, amount of formaldehyde = 70 Kmol/hr
Fresh water is added in stream 12 = 70 Kmol/hr (approx.)
Assuming 99.9% formaldehyde is absorbed
Amount of formaldehyde in stream 14 =69.93 Kmol/hr
Methanol in exit stream = 16.625 Kmol/hr
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REACTOR
The reactor used in the formaldehyde plant utilizes catalyst bed and has the shell
and tube heat exchanger located in it. The catalyst bed actually lies on the shell
and tube heat exchanger. The reaction takes place on the exchanger and as can be
seen from the rate equation is actually very fast. So, the diffusion or mass transfer
resistance is not considered in the reaction.
The use is made of rate equation in terms of moles of methanol consumed.
The reactor is made up of copper material and it is about 0.992 m in diameter. It
consists of a silver bed in the form of granules weighing about 25 kg. The silver bed
has the following layers:
6 copper screens and two silver screens at bottom. 1 silver screen is kept at top.
The temperature of the catalyst bed is maintained at about 600C. The heat
evolved from the highly exothermic reaction raises the temperature to 670-700C.
Also initially passing steam in the outer jacket raises the temperature. Air required
for the reaction is provided from the air valve provided near the reactor.
Here, the methanol vapours are converted into formaldehyde by an oxidation
reaction in the presence of silver catalyst.
The methanol vapours enter the reactor dome at a temperature of about 120C.
The methanol vapours are then converted into vapours of HCHO in the reactor in
the presence of high-pressure air and the high temperature of about 700C. The
vapours go down into the steam generator and then to the condenser.
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REACTOR HEAT CALCULATIONS
I Method.
Using Heat Of Reactions for different Reactions
Reaction No. Nature Moles Reacted Heat Of Reaction Heat
1 Exothermic 8.559 37.3
1335.74
5
2 Endothermc 5.706 20.3
484.640
3
3 Exothermic 1.538 162
1042.46
9
4 Exothermic
5 Exothermic 0.14 51
29.8737
6
6 Exothermic 0.14
II Method.
Using Heat Of Reaction Cumulatively
heat of
reaction 116.6 Kj/Kmol
heat released
1663.29
9 Kj/sec
HEAT BALANCE FOR REACTOR EFFLUENT GASE
Species Moles of Diff. Species Fraction
CH3OH 0.61
0.09610
8
HCHO 1
0.15755
5
H2 0.418
0.06585
8
CO2 0.22
0.03466
2
CO 0.13
0.02048
2
H2O 0.842
0.13266
1
O2 0.009
0.00141
8
N2 3.118
0.49125
6
Total 6.347
Formulae Of Specific Heat
Used
Specific Heat = a+b*T+c*T
2
+c*T
3
+d*T
4
Constants CH3OH HCHO H2 CO2 CO H2O O2
a 21.37 3.094 28.9105 21.3655 29.0277 32.4721 23.3768
b 0.070843
0.00387
7 0.00102
0.06428
1 -0.00282
7.96E-
05 -0.00406
c 0.00002586 -3.1E-06 -1.476E-07 -4.1E-05 1.16E- 1.32E- 1.04E-
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05 05 05
d -2.8497E-08
1.01E-
09 7.69E-10 9.8E-09 -4.7E-09 -4.5E-09 -3.9E-09
After Multiplying With
Fractions
Constants CH3OH HCHO H2 CO2 CO H2O O2
a 2.053657
0.48761
4 1.908093
0.74779
3
0.58055
4
4.31878
9
0.02337
7
b
0.00680801
2
0.00061
1
0.0000673
2 0.00225 -5.6E-05
1.06E-
05 -4.1E-06
c
2.48515E-
06 -4.9E-07
-9.7416E-
09 -1.4E-06
2.33E-
07
1.76E-
06
1.04E-
08
d
-2.73856E-
09
1.58E-
10
5.0754E-
11
3.43E-
10 -9.4E-11 -6E-10 -3.9E-12
Constants Total Heat
a 24.6490089
5003.74
9
b
0.00716214
6
791.846
1
c
9.02241E-
06
549.567
2
d
-5.32758E-
09 -180.783
Temperature Specifications of Inlet and Outlet reactor effluent gases
Inlet
Temperature deg. C 373 in K 646.13
Outlet
Temperature deg. C 170 in K 443.13
Energy Calculations
Heat Required
(Sp.
Heat.* KJ/Kmol
6164.37
9
Flow Rate of
Gases Moles/sec
90.5399
6
Heat Required
(flow Rate*Sp.
Heat.* KW
558.122
6
Cooling Medium is Water
Inlet Temperature of Water deg. C 25 in K 298.13
Outlet Temperature of Steam deg. C 204.44 in K 477.57
Specific Heat Of Water KJ/KgK 4.184
Total Heat To Be Quenched KW
2221.42
2
(Total heat is equal to latent heat and sensible heat)
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Steam
Enthalpy Btu/lb 826
Steam
Enthalpy KJ/Kg
1920.00
6
Flow Rate of Water is calculated by dividing the heat load by the temp. difference of
water and
the specific heat of water
Flow Rate of
Water Kg/sec
0.83174
9
Catalyst Calculations
Reaction Rate mole/Kg catalyst hr. K1*Pm/(1+K2Pm)
where K1& K2 are constants
P stands for pressure in atm.
m stands for methanol
Consatnts K1 K2
a 8.52 3810
b 10.79 7040
Temp. of Reaction in deg. C= 600 in K = 873.13
Consatnts log K1 2.727054 K1 533.4013
log K2 4.156389 K2 14334.7
Moles of Methanol Reacted
taking conversion into consideration for 1 mol formaldehyde
moles 1.13
Moles of Methanol Reacted taking conversion into consideration /hr
moles/hr 58030.02
Mole fraction of Meyhanol in gases coming to reactor
Moles of Methanol 0.644
Total Moles of Gase 1.487
fraction 0.433087
Reactor
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Conditions
Temp. 873.13 K
Pressure 1.1 atm
Partial Press. Of Methanol 0.476395
Amount of Catalyst Required Kg 25.32358
TABLE 7: SHELL DIA CORRELATION DATA FOR DIFFERENT ALLOYS
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HEIGHT AND DIAMETER
For the gases
Inlet Temperature in deg. C = 373 in K = 646.13
Outlet Temperature in deg. C = 170 in K = 443.13
For the water
Inlet Temperature in deg. C = 25 in K = 298.13
Outlet Temperature in deg. C = 204.44 in K = 477.57
Boiling Point in deg. C = 204.44 in K = 477.57
Total Heat to be Removed KW 2221.421577
Area Calculation
LMTD deg. C 358.05
R 1.39
S 0.318
Correction Factor (from graph) 0.92
Corrected LMTD 329.406
Taking U equals to W/m^2 deg. C 500
Area Outside
Reqd. m
2
13.48743846
Tuibes Used are 20 mm OD 16 mm ID and 4.88 m length
Area of One tube m
2
0.303
Number of Tubes 44.51299822 or 46
Triangular Pitch (1.25*OD) mm 25
Bend Radius (3*OD) mm 60
Tube Out Limit Dia. mm 495.3846154
Heat Flux (based on estimate area) KW/m^2 164.703
hnb W/m^2 25873
Heat Transfer Coeff. Calculation
Air Mixture Condensing Coeff. Is taken as 400 W/m^2
1/hnb 3.86503E-05
1/fouling factor for reactor gases 0.0001
1/heat transfer coeff. For tube wall 4.05716E-05
For Steam Side 0.0015625
1/Uo 0.001741722
Uo 574.1444765
Uo cimes out too close to assumed from value of 500 and higher so is in safe side
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Max. Allowable Heat Flux
surface Tension N/m 0.0352
Liq. density Kg/m^3 960
Vap. Density Kg/m^3 7.725
Number of Tubes 184
For square arrangement, Kb 0.41
Heat Flux 2055.62
Factor 0.7
Actual Max. Flux 1438.934
So, Its safe
Tube Sheet Layout, Bundle Dia., Db mm 496
Taking shell diameter to be 2 times bundle dia.
shell dia. mm 992
Liquid level from base mm 800
freeboard mm 192
Height of Catalyst Bed
Weight of Catalyst Kg 25.32357959
Density of Catalyst lb/ft^3 100
Kg/m^3 1601.85
Volume of Catalyst m^3 0.015808958
Dia of Catalyst Bed mm 992 inch 39.05512
Height of Catalyst Bed m 0.204519026
Lemgth of Tube m 4.88
Total m 5.084519026
taking a favtor of 1.5 to accommodate space on top and bottom
Total Height m 7.626778539
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ABSORPTION COLUMN
ABSORBER DESIGN
One of the most common unit operations in the industry is the absorption process.
Absorption is the mechanism of transporting molecules or components of gases into
liquid phase. The component that is absorbed is called the solute and the liquid
that absorbs the solute is called the solvent. Actually, the absorption can be either
physical where the gas is removed due to its high solubility in the solvent, or
chemical where the removed gas reacts with the solvent and remains in solution.
PACKED-BED ABSORBER
The packed-bed absorbers are the most common absorbers used for gas removal.
The absorbing liquid is dispersed over the packing material, which provides a large
surface area for gas-liquid contact. Packed beds are classified according to the
relative direction of gas-to-liquid flow into two types. The first one is co-current
while the second one the counter current packed bed absorber. The most common
packed-bed absorber is the counter-current flow tower. The gas stream enters the
bottom of the tower and flows upward through the packing material and exits from
the top after passing through a mist eliminator.
Liquid is introduced at the top of the packed bed by sprays or weirs and flows
downward over the packing. In this manner, the most dilute gas contacts the least
saturated absorbing liquid and the concentration difference between the liquid
and gas phases, which is necessary or mass transfer, is reasonably constant through
the column length. The maximum (L/G) in counter-current flow is limited by
flooding, which occurs when the upward force exerted by the gas is sufficient to
prevent the liquid from flowing downward. The minimum (L/G) is fixed to ensure
that a thin liquid film covered all the packing materials.
PACKING MATERIAL
The main purpose of the packing material is to give a large surface area for mass
transfer. However, the specific packing selected depends on the corrosiveness of
the contaminants and scrubbing liquid, the size of the absorber, the static pressure
drop, and the cost. There are three common types of packing material: Mesh,
Ring, and Saddles. In our project Ceramic Berl Saddles packed was selected since it
is good liquid distribution ratio, good corrosion resistance, most common with
aqueous corrosive fluids and Saddles are beast for redistributing liquids low cost.
Also we use 2 inches diameter packing.
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SIZING OF PACKED TOWER
ASSUMPTIONS
Some assumptions and conditions were design calculation based on:
1. G and L are representing the gas and liquid flow rates.
2. x and y are for the mole fraction of Methanol in liquid and gas respectively.
3. Assuming the column is packed with (2” Ceramic Berl_ Saddle).
PACKED TOWER DIAMETER:
Gas velocity is the main parameter affecting the size of a packed column. For
estimating flooding velocity and a minimum column diameter is to use a
generalized flooding and pressure drop correlation. One version of the flooding and
pressure drop relationship for a packed tower in the Sherwood correlation, shown
in Figure 2.
Packing diameter calculation:
The gas flow rate G= 6670.781 kg/h
The liquid flow rate L= 1549.818
Calculate the value of the abscissa ε
Where: L and G = mass flow rates (kg/h)
ρ_g = density of the gas stream
ρ_l = density of the absorbing liquid
ρ_g = 1.605 kg/m^3
ρ_l = 995 kg/m^3
Fp = 150m^(-1)
µ = 0.000797 P
gc = 9.8 m/s^2
Flow factor = 0.013706
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From the figure
using flooding line, ε = 0.2
Where
G' = mass flow rate of gas per unit cross-sectional area of column, g/s•m2
ρ_g = density of the gas stream
ρ_l = density of the absorbing liquid
gc = gravitational constant,
F = packing factor given
ᵠ = ratio of specific gravity of the scrubbing liquid to that of water
µ = viscosity of liquid
G‟flooding = 9.323643
G‟ operating = 0.55 (G‟ flooding) = 5.128
area of packing = 0.361348 (G/G‟operating)
D_packing = 0.6784m
Packing diameter, D_tower =0.8480 (D_packing*1.25)
column diameter = 1.0m (roundoff)
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CALCULATING NOG AND Z
Z= HOG *NOG
NOG = number of transfer units based on an overall gas-film coefficient.
HOG = height of a transfer unit based on an overall gas-film coefficient, m
yA,in = mole fraction of solute in entering gas
YA,out = mole fraction of solute in exiting gas
yA,in = 0.27778
yA,out = 0.007
Y*
A,in = 0.20
Y*
A,out = 0.0001
NOG = 9.2540
HOG obtained from table 15-4 in “Separation Process Engineering”.
For ceramic packing with size 2 inch,
HOG = 3 ft = 0.9 m
Z= HOG *NOG = 8.32 m
Z_column = Z_packing*(1+0.25)
Z_column = 10.41m
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DISTILLATION COLUMN
The problem of determining the stages and reflux requirements for
multicomponent distillations is much mo4re complex than for binary mixtures.
With a multicomponent mixture, fixing one component composition does not
uniquely determines the other component compositions and stage temperature.
Also when feed contains more than two components, it is not possible to specify
the complete composition of the top and the bottom products independently. The
separation between top and the bottom products is specified by setting limits on
two “key” components, between which it is deserved to make the separation.
KEY COMPONENTS
The light key will be the component that it is desired to keep out of the bottom
product, and the heavy key the component to be kept out of the top product.
Here the light component is Methanol while the heavy component being Water.
MULTICOMPONENT DISTILLATION FOR STAGE AND REFLUX
REQUIREMENT
Hengstebeck‟s Method:
For any component i the Lewis-Sorel material balance equation and equilibrium
relation can be written in terms of individual component molar flow rates; in the
place of component composition:
vn+1,i = ln+1 + di
vn, i = Kn, i (V/L) ln,i
For the stripping section :
l’n+1, i = v’n, 1 + bi
v’n, 1 = Kn, i (V’/L’) l’n,i
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where :
ln+1 = the liq. flow rate of any component i from the stage n,
vn, i = the vapour flow rate of any component i from the stage n,
di = the flow rate of the component i in the tops,
bi = the flow rate of the component i in the bottoms,
Kn, i = the equilibrium constant for component i at the stage n.
The subscript „ denotes the stripping section.
V and L being the total flow rates, assumed constant.
To reduce a multicomponent system to an equivalent binary system it is necessary
to estimate the flow rate of the key component throughout the column. This
method assumes that in a typical distillation the flow rates of each of the light
non-key components approaches a constant, limiting , rate in the rectifying
section; and the flow of each of the heavy non-key components approach limiting
flow rates in the stripping section.
Thus we have for the rectifying section :
Le = L - ∑li
Ve = V - ∑vi
And for the stripping section:
L’e = L’ - ∑l’i
V’e = V’ - ∑v’i
Where
Ve and Le are the estimated flow rates of the combined keys.
li and vi are the limiting liquid and vapour rates of the components lighter than the
keys in the rectifying section.
L‟i and v‟i are the limiting liquid and vapour rates of the components heavier than
the keys in the stripping section.
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Then we have:
li = di/(αi-1)
vi=li + di
v’i = αibi/(αLK-αi)
l’i = v’i + bi
where αi = relative volatility of the component i, relative to to the heavy key HK
and αLK = realtive volatility of the light key (LK), relative to the heavy key.
The equilibrium live was drawn using the relation
y= αLKx / ( 1 + (αLK-1)x )
where x and y refers to the liquid and vapour concentrations of the light key.
FINDING THE MINIMUM NUMBER OF STAGES
The Fenske equation have been used to estimate the minimum number of stages at
the total reflux condition. The equation is:
[ xi / xr ] = αi
Nm
[ xi / xr ]b
[ xi / xr ] = the ratio of the concentration of any component i to the concentration
of a reference component r and the suffixes b and d denote the distillate and the
bottoms respectively.
Nm = minimum number of stages at the total reflux condition.
αi = average relative volatility of the component i with respect to the reference
component.
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If the number of stages is known then the above equation can be used to estimate
the split of components between the top and the bottom at total reflux. Thus we
have:
di/ bi = αi
Nm
[ dr / br ]
Where di and bi are the flow rates of the component i in the tops and the
bottoms.
And dr and br are the flow rates of the reference component in the tops and the
bottoms.
We also have di + bi = fi wher fi is the flow rate of the component i.
MINIMUM REFLUX RATIO
The equation is:
∑ [αi xi,d / (αi - ɵ ] = Rm + 1
Where:
αi = relative volatility of component i with respect to some reference component,
usually the heavy key.
Rm = the minimum reflux ratio.
xi,d = concentration of component i in the tops and bottoms.
ɵ root of the equation : ∑ [αi xi,f / (αi - ɵ ] = 1-q
where xi,f = the concentration of the component i in the feed and q depends upon
the condition of the feed.
FEED POINT LOCATION
The empirical relation used is :
log [ Nr / Ns] = 0.206log[ ( B/D)( xf,HK/ xf,LK ) (xb,LK/ xb,HK)2
]
Nr = number of stages above the feed, including any partial condenser.
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Ns = number of stages below the feed, including the reboiler.
B = molar flow of bottom product.
D = molar flow of top product.
xf, HK = concentrations of the heavy key in the feed
xf, LK = concentrations of the light key in the feed.
xb, LK = concentrations of the heavy key in the top product.
xb, HK = concentrations of the light key if in the bottom product.
EFFICIENCY
The overall column efficiency is obtained by O‟ Connell correlation:
Eo = 51 – 32.5 log (µaαa)
Where µa = molar average liquid velocity.
αa = average molar volatility of the light key.
MATERIAL COMING FROM ABSORBER
MOLES/S MOL. WT. G/SEC
FLOW RATE OF METHANOL 8.70165 32.06 278.9749
FLOW RATE OF
WATER 41.4659 18 746.3862
FLOW RATE OF FORMALDEHYDE (IN WATER) 14.265 30.02 428.2353
TOTAL SOLUTION 64.43255 1453.5964
PERCENTAGE OF FORMALDEHYDE IN WATER 0.2213943 0.294604
PERCENTAGE OF METHANOL IN SOLUTION 0.1350505 0.1919205
OPERATING CONDITIONS AND VARIABLES
UNIT
PRESSURE OF THE COLUMN atm. 1
DEW
POINT deg C
66.5 deg
C
BUBBLE POINT deg C
97.6 deg
C
K's VALUES AT 1 atm AND DIFFERENT TEMP.
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Feed Specifications
COMPONENT FEED TOP BOTTOM
METHANOL 8.70165 8.151891 0.549759
WATER 40.3559 0.360068 40.78652
FORMALDEHYDE 14.265 0.014265 14.25074
TOTAL 63.32255 8.526224 55.58702
COMPONENT Xd Xb Xf
METHANOL 0.956096 0.00989 0.137418
WATER 0.042231 0.733742 0.637307
FORMALDEHYDE 0.001673 0.256368 0.225275
LIGHT KEY METHANOL
HEAVY KEY WATER
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BUBBLE POINT CALCULATION
TEMP.
150 deg
C 99.9 97.6
COMPONENTS Xb Ki Ki*Xi Ki Ki*Xi Ki Ki*Xi
METHANOL 0.00989 3.004 0.02971 2.595 0.025665 2.589 0.025605
WATER 0.733742 2.46 1.805005 1.198 0.879023 1.105 0.810785
FORMALDEHYDE 0.256368 1.22 0.312769 0.73 0.187149 0.693 0.177663
TOTAL 2.147484 1.091836 1.014053
BUBBLE POINT 97.6 deg C
DEW POINT CALCULATIONS
67.1 deg C 72.1 66.5 deg C
COMPONENTS Xd Ki Xd/Ki Ki Xd/Ki Ki Xd/Ki
METHANOL 0.956096 1.094 0.873945 1.435 0.666269 1.05 0.910568
WATER 0.042231 0.491 0.086009 0.394 0.107184 0.52 0.081213
FORMALDEHYDE 0.001673 0.266 0.00629 0.336 0.004979 0.26 0.006435
TOTAL 0.966245 0.778433 0.998216
DEW POINT TEMP. 66.5 deg C
EQUILIBRIUM DATA
RELATIVE VOLATILITY=Ki/K FOR HEABY KEY
TOP BOTTOM AVERAGE
TEMP. 66.5 97.6
COMPONENTS Ki Ai Ki Ai Ai
METHANOL 1.05 2.019231 2.589 2.342986 2.181109
WATER 0.52 1 1.105 1 1
FORMALDEHYDE 0.26 0.5 0.693 0.627149 0.563575
EQUIL. DATA: y=Ai(LK)*x/(1+ (Ai(LK) - 1)*x) OPERATING LINES
TOP BOTTOM
X Y X Y X Y
0 0 0.958 0.957699 0 0.0133
0.1 0.195071 0.209 0.32168 0.2 0.328138
0.2 0.352867
0.3 0.48314 NO. OF STAGES DATA
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0.4 0.592514 X Y X Y
0.5 0.685644 0.013 0.0133 0.249776 0.4
0.6 0.765899 0.013 0.02856 0.249776 0.4
0.7 0.835776 0.023 0.02856 0.325915 0.4
0.8 0.897166 0.023 0.048442 0.325915 0.5
0.9 0.951527 0.035 0.048442 0.434847 0.5
1 1 0.035 0.073698 0.434847 0.6
0.051 0.073698 0.568191 0.6
Line: Y=X 0.051 0.104778 0.568191 0.7
X Y 0.07 0.104778 0.703466 0.7
0 0 0.07 0.141559 0.703466 0.8
1 1 0.093 0.141559 0.81692 0.8
0.093 0.18313 0.81692 0.9
0.119 0.18313 0.897845 0.9
0.119 0.22774 0.897845 1
Sample Point calculations 0.147 0.22774 0.949137 1
EQUIL. POINT 0.147 0.273025 0.949137 1
X Y 0.175 0.273025
0.949137 0.97602 0.175 0.316474
0.202 0.316474
BOTTOM OPERATING LINE POINT 0.202 0.355965
X Y 0.25 0.355965
0.202175 0.316474
TOP OPERATING LINE POINT
X Y
0.949137 0.950421
TOP BOTTOM
MOLE/S Ai Li Vi MOLE/S Ai Vi Li
8.151891 2.181109 6.901898 15.05379 14.25074 0.6 4.965182 19.2159
TOTAL 6.901898 15.05379 4.965182 19.2159
(CHOOSING REFLUX RATIO OF 1.5 TIMES MIN. REFLUX RATIO)
EQUIL. L 57.84328 EQUIL. L 110
EQUIL
V. 58.21762 EQUIL. V 68
SLOPE OF OPERATING LINE (TOP) SLOPE OF OPERATING LINE (BOTT
EQUIL L/EQUIL V 0.85
EQUIL
L/EQUIL V 1.605161
xb 0.0133
xd 0.957699
xf 0.177376
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MIN. REFLUX RATIO
5.06243
5
Calculations For Entering the feed
Xb(LK) 0.00989
Xd(HK)
0.04223
1
Xf(LK)
0.13741
8
Xf(HK)
0.63730
7
Method Employed is Kirkbride equation
Total Bottom
product
55.5870
2
Total Distillate product
8.52622
4
log (Nr/Ns)
0.04524
8
Nr/Ns 1.1098
Total Number of stages 18
Total Number of stages excluding Reboiler and Condenser 17
Ns
8.05763
6
so the feed should enter at the plate 8
From the graph it comes out to be 9
Approximately equal
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0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 0.2 0.4 0.6 0.8 1
molefractionofFormaldehydeinMethanol
mole fraction of Formaldehyde in Water
FIGURE 9: Equilibrium data and number of Stages
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Dia And Height Calculation
Number Of Stages: 18
Slope of Top Operating Line 0.85
Slope of Bottom Operating Line 1.605161
Top Composition (Essentially Methanol) 96
Bottom Composition (Essentially Formalin) % Formaldehyde 26
Reflux Ratio 7.593
Flow Rate in gm/sec 1453.596
Flow Rate in moles/sec 64.43255
Flow Rate in Kg/hr 5232.947
Top Product 965.7327
Vapor Rate at Top 8298.541
Bottom Product 4267.214
Material Balance Gives:
Vm at bottom 7051.367
Liq. Flow Rate at Bottom 4392.934
Column Efficiency in % 60
Real Stages 28.33333 or 29
Assuming 100 mm water Pressure Drop per Plate (All in Pa)
Column pressure Drop 28449
Top Pressure Drop 101325
Bottom pressure 129774
Base Densities:
Liquid Density 1111
Vapor Density 0.695
Surface Tension 0.018
Top Densities:
Liquid Density 792
Vapor Density 1.13073
Surface Tension 0.0469
Tray Spacing taken to be 0.5 m
Column Diameter: K1
F(LV) at Bottom 0.040147 0.08
F(LV) at Top 0.032117 0.08
Correction For Surface Tension
At Bottom 0.078332
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At Top 0.094868
Base Velocity: in m/sec 3.130886
Top Velocity: in m/sec 2.508947
Designing Done for 85 % flooding
Base Velocity: in m/sec
2.66125
3
Top Velocity: in m/sec
2.13260
5
Maximum Flow Rate
Base m^ 3/sec
2.81829
2
Top m^ 3/sec
2.03863
9
Net Area Reqd.
Base m^ 2
1.05900
9
Top m^ 2
0.95593
9
Downcomer Area Taken as 12 % of total Area
Base m^ 2 1.20342
Top m^ 2
1.08629
4
Column Diameter:
Base m
1.23775
7
Top m
1.17598
2
Height Claculation:
Totla Number of Trays 29
Crude Hright for Column m 14.5
(number of stages * tray spacing)
Choosing 30 % more space for free space at top and bottom
Additional Hright m 4.35
Total height m 18.85
Or after rounding off, Total height m 19
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Number of stages after taking efficiency into consideration
Top Temperature in º C 66.5
Bottom Temperature in º C 97.6
Average Temperature in º C 82.05
Vicosities:
Methanol 0.29
Water 0.35
Formaldehyde 1.87
Molar Average Viscosity in Feed 0.684
Average viscosity for Light Key
2.18110
9
so Efficiency from graph almost 100%
so Number of stages is still 18
Number of Stages (Real, 60% column efficiency) 29
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CONDENSER
Shell and tube exchangers can be effectively used as condensers which are
employed more preferably than direct contact condensers. There are 4 types of
condenser configurations available. They are :
1. Horizontal, with condensation in shell and cooling medium in tubes.
2. Horizontal, with condensation in tubes and cooling medium in shell.
3. Vertical, with condensation in shell and cooling medium in tubes.
4. Vertical, with condensation in tubes and cooling medium in shell.
Of which horizontal shell side and vertical tube side are the most commonly used
ones. A horizontal exchanger with condensation in tubes is rarely used as a process
condensers but is the usual arrangement for heaters and vaporizers using
condensing steam as the heating medium.
In the formaldehyde process, the condenser used is total condenser. The outlet
stream is condensed methanol which is recycled back to the fresh feed. Thus the
overall economy of the process increases. The reflux ratio of 1.5 times the
minimum is utilized in the distillation column which gives the amount of methanol
recycled and produced.
Condenser Mainly has Methanol Condensing in it With Small Amount of
Water Present in it
COMPONENT TOP Xd
METHANOL 8.151891 0.956096
WATER 0.360068 0.042231
FORMALDEHYDE 0.014265 0.001673
Feed
TOTAL 63.32255 8.526224
Average Molecular Weight of Vapors 31.5
(For Simplicity Taken As 96 % Methanol And 4% Water)
Condensing Temp. of Methanol 64 deg. C
(Taken fom J. H. Perry)
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Actual Condensing Temp. of Methanol deg. C 50
(Design Temp. of Condnsation)
Inlet Temp. of Methanol Vapors deg. C 66.5
Cooling Medium Cold Water
Water Inlet Temp. deg. C 25
Water Inlet Temp. (max.) deg. C 35
Enthalpy of Sat. Vap. KJ/Kg 1492.1
Enthalpy of Sat.
Liq. KJ/Kg 391.7
Flow Rate of Methanol 965.7326988
Heat transferred from Vapor KW 295.1922949
(Flow rate of methanol * (Enthalpy of Sat. Vap.- Enthalpy of Sat. Liquid)
Cooling Water Flow Kg/sec 7.062016626
(Heat reqd. for condensatio/(temp. diff.* sp. Heat))
Assumed Overall Coefficient W/m^2 deg. C 500
LMTD Calculations:
Temp. correction factor R 1.65
S 0.240964
LMTD Temp. deg. C 28.12493
Correction Factor Ft 0.96
Corrected LMTD Ft*LMTD 26.99993
Choosing 20 mm O.D. 16.8 mm I.D. 4.88 m (16 ft) long brass tubes
Tube ID mm 16.8
Tube OD mm 20
Tube Length m 4.88
Trial Area m^2 21.86615
( Heat Required/(Assumed U* LMTD))
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Number of Tubes 71.30441 or
(Area of heat trensfer reqd./ area of one tube) 72
Employing One Shell Two Tube Pass
Triangular Pitch since fouling is very less mm 25
Tube Bundle Dia., Db mm 260.7226
Number of Tubes in Center 10.4289
Shell side Heat Tranfer Coeff. Calculation
Assumed Shell-side Coefficient W/m^2 deg. C 3500
From the Chart given in Coulson Richardson, Vol. 6
Mean Temp.
Shell-side deg. C 58.25
Tube-side deg. C 30
(H51-Tw) deg. C 4.035714
Tw 54.21429
Mean Condensate Temp. deg. C 56.23214
Viscosity
mN
s/m^2 0.38
Liq. Density Kg/m^3 792
Vap. Density Kg/m^3 1.13073
K (thermal conductivity) W/m deg. C 0.192
Load Kg/sm 0.000763
where
Nt total number of tubes in the bundle
L tube length
wc
total condensate
flow
Nr = 2*Number of tubes in center/3 6.952603
average number of tubes in the bundle
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Heat Transfer Coeff. W/m^2 deg. C 3652.902
So, Heat Transfer Coeff. Came quite close
Tube side Heat Transfer coeff.
Tube-Side Coefficient. W/m^2 deg. C
Tube Cross Sectional Area m^2 0.003991
Density of Water Kg/m^3 994
Tube Velocity m/sec 1.780349
Tube-Side heat trasf.Coeft.. W/m^2 deg. C 7389.688
Over-All Heat Transfer Coeff. W/m^2 deg. C
Fouling Factors for Both side W/m^2 deg. C 2000
Conductive Heat Transf. Coeff.of Tubes 50
1/U 0.001565
1/U= outer dia*inner dia./tube side coeff. + 1/shell side coeff. +1/foulingcoeff.
...+ outer dia./(fouling*inner dia) + outer dia.*LN(outer dia./innerdia)/(2*tube thermal conductivity)
U
(inverse of
1/U) 638.9926
Since, U comes out close to assumed heat transfer coeff. Of 500
And the deviation is on positive side. We can take the arrangement
of shell and tube condenser as above to be satisfactory
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REBOILERS
Reboilers are used with distillation columns to vaporize a fraction of bottom
product whereas in a vaporizer essentially all feed is vaporized thus in this way
they differ from a vaporized.
TYPES OF REBOILERS
Forced circulation: pump is required for this kind of reboiler. It is used
essentially for reboiling viscous and fouling fluids.
Thermosyphon natural circulation reboiler: it can be horizontal or vertical.
Liquid circulation is maintained by the difference and density between two-
phase mixture of vapour and liquid. A disengagement vessel will be required
for this reboiler.
Cattle type reboiler: Boiling takes place on tubes immersed in a pool of
liquid. There no circulation of liquid through exchanger and they are not
suitable for fouling materials and have a high residence time.
SELECTION OF REBOILER
In our case, Thermosyphon reboiler is used. In this type, the heat available in
bottom feed is utilized. This type of reboiler requires a minimum head so that it
can take advantage of density difference thus the support of distillation column
and reboiler needs to be elevated and the cost increases. But the higher cost is
offset by the economic usage of available heat which otherwise would have been
lost.
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BOILER DESIGN
COMPONENT FEED TOP BOTTOM
METHANOL 8.70165 8.151891 0.549759
WATER 40.3559 0.360068 40.78652
FORMALDEHYDE 14.265 0.014265 14.25074
TOTAL 63.32255 8.526224 55.58702
COMPONENT Xd Xb Xf
METHANOL 0.956096 0.00989 0.137418
WATER 0.042231 0.733742 0.637307
FORMALDEHYDE 0.001673 0.256368 0.225275
LIGHT KEY METHANOL
HEAVY KEY WATER
Vaporisation Rate Reqd. Kg/hr 7051.367
Boiling Point of Formalin solution deg. C 99.7
Steam available at Pressure atm. 2.85
Temp. deg. C 132.22
(Ref: McCabe Smith, Appendix 8)
Latent Heat of Vaporisation KJ/Kmol 30176
(Ref: McCabe Smith, Appendix 3)
Critical
Temperature deg. C 586.0482
(Ref: J. H. Perry)
Mean Overall diff.
T deg. C 32.52
Reduced Temp. deg. C 0.635955
(Boiling Point in K/Critical Temp.)
Molecular Weight 21.152
From Fig. Heat Flux W/m^2 deg C 42000
Heat Load KW 592.8398
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(Flow Rate*Latent Heat of Vaporisation/(3600*Boiling Point)
Area Required m^2 14.11523
(Heat Load/ Heat Flux)
Choosing 20 mm O.D. 16.8 mm I.D. 4.88 m (16 ft) long brass tubes
Tube ID mm 16.8
Tube OD mm 20
Tube Length m 4.88
Area of one tube m^2 0.303
Number of Tubes reqd. 46.58493
Calculation for Bundle Dia. 207.77
A dixed tube sheet can be used for a thermosyphon reboiler
(from fig. 12.10, diametrical clearence)
Diametrical Clearence mm 14
Shell Inside dia. mm 221.77
( Bundle dia. + diametrical clearence )
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PHYSICAL DESIGNING OF SOME OTHER EQUIPMENTS
The plant has beside the major equipments like reactor, distillation column and
absorber column several other heat tansfer and mass transfer equipments. For
example; heat exchangers are used extensively in the chemical plants. These heat
exchangers are required for utilising the heat in the effluent gases. Furnaces are
there to provide extra heat needed and which is not available in the process
streams. Likewise, pumps, compressors and blowers are used to transfer solid,
liquid and gases. A sample designing of some them used in the formaldehyde plant
is given here.
PUMPS
Total moles of methanol( feed + recycle) for 1 mol of formaldehyde = 1.74
HCHO production rate = 14.265 mols / sec
Hence methanol reqd. = 1.74 * 14.265 = 24.8215 mol / sec
Viscosity of methanol at 35o
C = .48 Cp
(reference J.H.Perry , nomograph for viscosity of liquids )
weight of methanol = 24. 8215 * 32.06 = 7.96 Kg / sec
Density of methanol = 1015 Kg/m3
Flow rate of methanol = 0.808 * 10-3
m3
/sec
SELECTION OF PUMP
Using graph between flow rate on x axis and pressure required on y axis from
Donald R Woods suitable pump is Centrifugal Pump.
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Head to be developed = 35- 14.7 = 20.3 Psia. = 1.05 m of water.
Single stage Centrifugal pump is sufficient.
Power required ( reference : fig 2-29 , page 2-27 , D R Woods)
Liquid flow rate = 0.808 L/Sec
Head = 1.05 m of water.
Now assuming 60% efficiency of the pump ,
The pump gives 0.1 KW for water so for methanol=0.1 * 1.015=0.1015 KW
Pipe size selection
Choosing from pump-heat exchanger combination pipe size available from [ fig 2-
30 , Page 2-28 ,D.R. Woods]
Pipe size available = 2.5 cm.
Velocity of methanol = v * 3.142 * d2
/4 = 0.808 L/sec
Hence v = 1.64 m/sec
Pressure loss
∆P / g = 4f( L/ D)* (<v>2
/ 2g)
thus ∆P/ 100m = 4 * 0.009 * 1015 * 100 * 1.642
/ ( 2.5 * 10-2
) = 393 KPa / 100 m
Reynolds no. = d v ρ / µ=2.5 * 10-2
* 1.64 * 1015 / (0.48 * 10-3
) = 86697.92
Material K K /D f
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Cast Iron 0.00085 0.0016 0.009
Wrought Iron 0.00015 0.000292 0.0038
(reference : Mc Cabe Smith , Page 101 , ed 4th
)
NPSH required = (pressures supplied at flange)- ( vapour pressure of liquid at
pumping temperature + friction losses )
Vapour pressure of methanol at 35 o
C ( 308 K)
Ln P = 7.209 – (1582.30 / ( T – 33.45))
Ln P = 7.209 – (1582.30 / ( 308 – 33.45))
= 1.445
thus P = 27.91 KPa
NPSH required = 101.325 – 27.91 KPa = 83.525 KPa = 0.64 m water head
BLOWER
Air required per mol of HCHO = 4.019 moles.
100 tonnes/ day of HCHO means
(100 * 103
* 103
* 0.37 ) / ( 30.02 * 24 * 3600) = 14.265 moles/ sec
So air required = 57.332 moles
Taking air to be an ideal gas amd air entering at the room temp. and at a pressure
of 14.7 psia.
Volume of air required per sec
= 57.332 * 22.4 * 10-3
= 1.284 m3
/ sec = 1284 dm3
/ sec
Pressure at which air is reached = 35 psia.
∆P= 35 – 14.7 psia = 20.3 psia.=139.925 KPa.
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Here multi stage blower have to be used.
Efficiency is taken to be 80% for compressors and 60% for fans.
Compressors used here are of 250 KW
At inlet pressure ( 14.7 psia or 100 KPa) so pipe would be 10 cm in dia. [ fig 2-13]
Velocity = 20m/sec
At outlet pressure ( 35 psia) so the fig [ fig 2-13] cannot be used.
ρ1= MP1/RT
ρ2= MP2/RT
Thus we have d2= d1 ( P1 / P2)1/2
hence d2 = 10 (35 / 14.7) cm = 15.43 cm.
PRESSURE DROP
∆P / g = 4f( L/ D)* (<v>2
/ 2g)
thus ∆P/ L = 4* 0.0032 * 20 * 20 * 1.1614 /( 2 * 50 * 10-2
)
= 7.06 KPa / 100 m.
Reynolds no. = d1 v ρ1 / µ
d1 = 10 * 10-2
m
v = 20 m /sec.
µ= 0.185 * 10-4
pa
(reference : J.H. Perry , Table 2.229)
Re = 10 * 10-2
* 20 * 1.1614 / ( 0.185 * 10-4
) = 1.256 * 105
(reference : Mc Cabe Smith , Page 101 , ed 4th
)
Material K K /D f
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Cast Iron 0.00085 0.0016 0.0062
Wrought Iron 0.00015 0.000292 0.0038
VALVE DESIGN
Valves are used to control pressure condition of flowing streams. Valves and vents
are needed as the as like in the reactor, the reactions might be occuring at the
high pressure. But the downstream gases, in this case going to absorber needs to
be brought down in the pressure.
Incoming Pressure = 25 psia.
Outgoing Pressure = 16.17 psia
Pressure equation is:
∆P = k * 0.6 * ρ * v2
/(1.22 *10)
where k = length factor for the valves
ρ = density of fluid
v = velocity of fluid
ρ = density of gases = M * P/(R * T)
where M = Avg. Mol. Wt.
P = pressure of gases
R = Universal Gas Constant
T = Temp.
ρ = 25.68 * 25 / 14.7
0.0821 * 616
ρ = 0.864 Kg/m3
∆P = (25 – 16.17)/14.7 *76
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this gives k = ∆P * 1.22 *10/( 0.6 * ρ * v2
)
k = 6.08
so, we can use globe valve
equivalent L/D = 320
Similarly, other valves can be designed as given.
AIR FILTER
Air-Filter Types Air filters may be broadly divided into two classes:
(1) Panel, or unit, filters;
(2) Automatic, or continuous, filters.
Panel filters are constructed in units of convenient size (commonly 20- by 20-in or
24- by 24-in face area) to facilitate installation, maintenance, and cleaning. Each
unit consists of a cleanable or replaceable cell or filter pad in a substantial frame
that may be bolted to the frames of similar units to form an airtight partition
between the source of the dusty air and the destination of the cleaned air. Panel
filters may use either viscous or dry filter media. Viscous filters are so called
because the filter medium is coated with a tacky liquid of high viscosity (e.g.,
mineral oil and adhesives) to retain the dust. The filter pad consists of an assembly
of coarse fibers (now usually metal, glass, or plastic). Because the fibers are
coarse and the media are highly porous, resistance to air flow is low and high
filtration velocities can be used. Dry filters are usually deeper than viscous filters.
The dry filter media use finer fibers and have much smaller pores than the viscous
media and need not rely on an oil coating to retain collected dust.
Automatic filters are made with either viscous-coated or dry filter media.
However, the cleaning or disposal of the loaded medium is essentially continuous
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and automatic. In most such devices the air passes horizontally through a movable
filter curtain.
HEPA (HIGH-EFFICIENCY PARTICULATE AIR) FILTERS
These were originally developed for nuclear and military applications but are now
widely used and are manufactured by numerous companies. By definition, an HEPA
filter is a “throwaway, extended-medium dry-type” filter having (1) a minimum
particle-removal efficiency of not less than 99.97 percent for 0.3-mm particles, (2)
a maximum resistance, when clean, of 1.0 in water when operated at rated air-
flow capacity, and (3) a rigid casing extending the full depth of the medium
(Burchsted et al., op. cit.). The filter medium is a paper made of submicrometer
glass fibers in a matrix of larger-diameter (1- to 4-mm) glass fibers. An organic
binder is added during the papermaking process to hold the fibers and give the
paper added tensile strength. Filter units are made in several
standard sizes. Air filters used in nuclear facilities as prefilters and buildingsupply
air filters are classified as shown in Table 17-10.
TABLE 9.
Other table presents the relative performance of Group I, II, and III filters with
respect to airflow capacity, resistance, and dust holding capacity. The dust-
holding capacities correspond to the manufacturers‟ recommended maximum
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allowable increases in airflow resistance. The values for dust-holding capacity are
based on tests with a synthetic dust and hence are relative. The actual dust-
holding capacity in a specific application will depend on the characteristics of the
dust encountered. In some instances it may be appropriate to use two or more
stages of precleaning in air-filter systems to achieve a desired combination of
operating life and efficiency. In very dusty locations, inertial devices such as
multiple small cyclones may be used as first-stage separators.
Table 10 : Air Flow Capacities and Resistance Holding Capacity for different
Filters
Table 11 : Removal Efficiency of different Filters
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MECHANICAL DESIGN
REACTOR MECHANICAL DESIGN
Reactor Data
Diameter = 1.2 m
Height = 6 m
Top and Bottom: Toro spherical head
Operating Pressure of Reactor: 1.1 atm.
Operating Temperature of Reactor: 873 K
Thickness of Shell, t= p*d/(2*f*E) + c
Where c= corrosion allowance
E= 13.37 Kg/m2
t = 16.8*1.01325*10 5/(2*13.37*10 6* 0.85)=7.4 mm
c= 3 mm
hence t= 10mm
Torospherical head figure 11: Torospherical Head
(Ri- ri)2
– (Ri-hi)2
= (R-ri) b
or Ri-hi = ((Ri - R)- (Ri + R-2ri))1/2 S
f Ri
Considering : Ri / D = 0.8 R
Or Ri = 0.8 * 1200 mm = 960 mm
Also ri / D = 0.1
Or ri = 0.1 * 1200 mm = 120mm
hi = 960 – ((960 – 496 )( 960+496-2*120))1/2
= 223.74 mm
zi = hi / 3 = 223.24 / 3 = 74.58mm
now, the volume of the head is given by
vh = (∏D2
L / 4 + 0.7D3
/2)
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where D is 1200 mm
l= 74.58 mm
hence vh = 0.4 m3
Thickness of head
t=p * w /(2fE-0.2* p) + c
where t = thickness of head.
P = pressure inside vessel.
W = stress intensification factor for torospherical dished head.
c= corrosion allowance
w = ¼ * ( 3 + ( rc / ri)1/2
)
w = ¼ * ( 3 + ( 960 /120)1/2
) = 1.46
p= 1.68 kg/mm2
hence t = 1.68 * 960 * 1.46 / (2 * 13.37 * 0.85 –0.2 * 1.68) = 2.14 mm
but the minimum thickness has to be taken = 3 mm
corossion allowance = 3 mm
hence total thickness = 6 mm
Design of flat head
p= 1.1 * 101.325 / 1000. = 0.1114 kg/mm2
t = D * (∆p / fall)0.5
=0.05 mm
but the minimum thickness has to be taken = 3 mm
corrosion allowance = 3 mm
Hence total thickness = 6 mm
2 openings are to be provided for water inlet and steam outlet.
And 2 openings are to be provided for inlet gases and outlet reactor effluent stream.
Velocity of gases maintained :
Velocity in tube = tube length / residence time = 6 / 0.02 = 300 m/ sec.
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Area of tubes * vt = area of shell * vs
vs = vt * (Dt / Ds )2
vs = 224 * ( 16 / 992)2
= 0.56 m/sec
But due to some velocity head loss and since the velocity of gases before entering the
reactor was 2 m/sec it is not changed and kept as it is. Also high velocity in the shell
means correspondingly high velocity in tubes so the mean residence time will further
decrease from 0.02 sec to some lower value which is highly desirable because it will
reduce the amount of formic acid formed.
NOZZLE DESIGN
Velocity of gases = 2 m /sec
Volumetric flow rate of the mixture = 2.131 mol/sec per mol of formaldehyde.
= 33.37 litre/ sec mol = 71.11 * 10-3
m3
/sec
Calculation of diameter
∏*D2
* v / 4 = Volumetric flow rate of the mixture.
D = ( 71.11 * 10-3
* 14.265 * 4 / ( 2 * 3.142))0.5
= 80.45 cm.
Optimum diameter for nozzle:
dopt = 282 * G0.52
* ρ
-0.37
where G = flow rate in kg /sec
ρ=density of gas
on calculations dopt = 267 mm
choosing dia of 270 mm
Area to be compensated = 6 * 270 = 1620 mm2
Taking h2 = 1.5 * dn = 1.5 * 270 = 405 mm
Area of compensation provided by portion of nozzle outside reactor
= 2 * 202.5 (tn -1.75 - 3)
Area of compensation provided by portion of nozzle inside reactor
= 2 * 202.5 (tn – 3)
Area of compensation adjacent shell material = 270 * (6-1.75-3)
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Equating above areas of compensation to total area of compensation
2 * 202.5 (tn -1.75 - 3) + 2 * 202.5 (tn – 3) + 270 * (6-1.75-3) = 1620
on calculations tn = 4.86 mm ( taken as 5mm)
Similarly the design was done for the liquid water inlet. Whose diameter comes out to be 80
mm.
Support Design
(Reference Process Equipment Design – 2nd
Edition by M.V. Joshi Page 367).
Diameter of vessel = 1.2 m
Height of vessel = 6 m
thickness of vessel = 10 mm (shell)
For head
thickness = 6 mm
Straight portion of head = 0.5m
effective height of head = .4123m
density of carbon steel = PS = .286 lb/ Cu-1n
= .286 (12)3
lb/ cu – ft
= 494 .208 lb/ cu-ft
= 16.018 494 – 208
= 7916 K S /m3
Di = 1.2m D0 = 1.22 cm, H = 9.6 m
weight of shell = si PHDD
22
0
4
= 791636.7992.002.1
4
22
= 915 .3 kgf
weight of head = ssi phDD
22
0
4
sprr
3
1
3
0
3
2
79165.0992.002.1
4
22
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79160992.1072.
3
2 33
=63 Kgf
weight of liquid (EDC) filled in reactor
height of liquid
HpDweight i 0
2
4
4
4.088.410000.14992.0
4
32
= 4526 Kgf
Total weight of Reactor = 915.3 + 63 + 4526
5500 kgf (indudiny wt. of nozzle & other aceessories)
Total Weight = Weight of Vessel + Attachments + Catalyst Weight
Since this weight is much appreciable so lug support will not work here, so we go for
skirt support.
Skirt Support for vertical cylindrical vessel
Diameter of vessel = 0.992 m = 992 mm
Height of vessel = 7.36m = 7360 mm
Weight of vessel + attachments = 5000 kg.
Diameter of skirt (straight) = 992 mm
Height of skirt = 1.0 m
Wind pressure = 128.5 kg/m2
Skirt
Stress due to dead weight (draw diagram on page 367 M.V. Joshi)
ktkD
f
s0
w
0
w dead wt. of vessel contents and attachments
D0k = Outside diameter of skirt
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tsk = thickness of skirt
2
0 /
73.17
2.99
5525
cmkg
ktkt
f
ss
Stress due to wind load
ktkD
Mw4
fwb
s
2
0
Z
H
PlwM (for H 20m)
011lw DhkpP up to 20m height
P1 = wind pressure for lower part of vessel
k1
= coefficient depending on the shape factor (0.7 for cylindrical surface)
D0 = outside diameter of vessel
2
H
Dhkpm 011
ktkD
2/HDhkp.4
f
s
2
0
011
wb
kt
f
s
wb 2
100992.0
100
2
36.7
992.036.75.1287.04
2
/
27.31
cmkg
kts
Stress due to seismic load
kt.Rok
WC
3
2
fsb
s
2
C = seismic coffecient = .08
W = total weight of vessel
Rok = outside radius of skirt
tsk = Skirt thickness
kt
bf
s
s 2
2
100992.0
552508.3/2
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2
/
03813.
cmkg
kts
Maximum tensile stress at bottom of skirt
bfbforbfmaxf aswmaxt
2
/
5.1377.1727.31
cmkg
ktktkt sss
Permissible tensile stress = 1400 kg /cm2
cmcmkts 00964.
1400
5.13
.0964 mm
Maximum compressive stress on skirt from equation
absbwb fforfmax
ktkttsk ss /09.48/77.17/27.31
intpoyield
3
1
lepermisssibfs
2
/666
3
2000
cmkg
cmcmkts 0721.0
666
09.48
Use a minimum thickness of 6 mm.
Skirt bearing plate
Assuming bolt circle diameter = Skirt diameter + 32.5 cm
=99.2 + 10.75 = 109.95 cm
Compressive stress between bearing plate and concrete foundation
Z
M
A
f ww
c
w = weight of vessel, contents & attachment
A = area of contact between bearing plate & foundation
Mw = bending moment due to wind
Z = Section modulus of area’
011e DhpkP
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2
H
Dhpk
2
H
pM 011lww
22
2.9995.109
45525
fc
95.10932
2.9995.109
5.11992.05.1287.0
44
= 33.123 + .018 = 33.14 kg/cm2
which is less than the permissible value for concrete.
Maximum bending moment in bearing plate
2
bl
fM
2
cmax
l = difference between outer radius of beaving plate and outer radil of skirt
b = circumferential length
b
b
M
35.420
2
25.161837.3
max
2
Stress 22
max
.
35.42066
BB tb
b
tb
M
f
2
2
/
09.2522
cmkg
tB
Permissible stress in bending is 1575 kg/cm2
222
0166.0
1575
09.2522
cmEmtB
cm
tB 16.
1.6 mm
Since the calculated thickness is less than 12 mm a steel rolled angle may be used as a
beaqring plate. Bolting chair need not be used.
FLANGE DESIGN:
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Design Pressure = 1.1 atm = 16.17 psia
Design temperature = 873 K
Flange material = ASTM A 201, Grade B
Bolting Material = ASTM A –193, Grade B –7
Gasket material = asbestos composition
Nozzle outside diameter = 0.280 m
Nozzle inside diameter = 0.270 m
Allowable stress of flange = 15000 psi
Allowable stress of bolting material =20000 psi
Calculation of Gasket width
do/di = ((y-pm)/(y-p(m+1)))0.5
Assuming a gasket thickness of 1/16 = 1.58 mm
y = 1600
m = 2.00
do/di = ((1600 – 14.7 –2)/(1600-14.7 *3)0.5
= 1.0052
Suppose di = 11.02
So do = 11.08
Minimum Gasket width = (11.08 – 11.02)/2 = 0.03
Which is too less, so we shall go for an 1/2 width gasket b =0.50
Mean gasket diameter = 11.02 + 0.50 = 11.52
Calculation of bolt loads
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bo = n /2 = 0.50 /2 = 0.25 ; Now bo <=0.25
Load of seat Gasket
Hy = bGy
So, Wm2 = Hy = 0.5 * 3.14 * 11.52 * 1600
= 28938 lb
Load to keep joint tight under operation
Hp = 2bGmp
= 2 * 0.5 * 3.14 * 11.52 * 2.00 * 16.17
= 1170 lb
Load from internal pressure
H = G2
p/4 = 3.142 * 11.52^2 * 16.17 / 4
= 3600 lb
Total operating load
Wm1= H +Hp = 1170 + 3600
= 4770 lb
Wm2 > Wm1
So controlling load is Wm2 = 28938 lb
Calculation of minimum bolting area
Am1 = Wm2 / fb = 28938 / 20000 = 1.4469 in2
Calculation of optimum bolt size
Bolt size Root area Min no. of Bolts Actual Number
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¾ 0.302 4.79 8
So, Bolt circle diameter = 11.52 + 2* (1.415 * 0.00236 +9/8)
=16.92”
So,
B = 11.02” =0.280 m
A = 20.87” = 0.530m
C = 16.92” = 0.430 m
E =13/16” =0.8125” = 0.0206m
go = 0.236” = 0.006 m
R = 9/8 = 0.033 m
G = 3.425” = 0.087 m
t = 0.096 m
h = 0.175 m
Bolt diameter = 1/2
No. of bolts = 4 (for symmetricity)
Flange O.D. = Bolt circle diameter + 2E
= 16.92 + 2 * 13/16
=16.92 + 1.625
=20.87”
MECHANICAL DESIGN OF ABSORBER
Calculate Di =2.56 m
Shell thickness
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Working Pressure = 1.3786 105
N/m2
Working Temperature = 300
C
Hydrostatic head = H g
here we consider as density of water because we are using water as on absorbing
medium
Hydrostatic head = Hg
= 10.62x103
x 9.81
=104.82 103
N/m2
weight of packing approximately
= gHP
4
2
= 8.962.1056.3
4
609
2
= 63.44 KN/m2
Design Pressure = 23
/1044.3.182.104.86.13705.1 mN
= 320.71 KN/mm2
PJf2
PDi
t
Material Selection – Stainless Steel
for this material fall 300
C = 165 106
N/m2
Assuming Double welded butt joint with spot radiography J = 0.85
56
5
102071.3101652
56.3102071.3
t mm
= 4.1 mm
Ref. (Coulson & Richardson Volume – 6 , Page 641)
Minimum practical wall thickness (including corrosion allowance = 3 mm)
So, t = 8mm
Thickness of wall = 5 mm (including corrosion allowance = 2 mm)
mDo 008.256.3
= 3.576 m
Torispherical Head design
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Do = 3.576 m
Let Ri = inside crown radius = Do = 3.576 m
ri = inside knucelete radius = .06 Di
= .06 * 3.56 = .2136 m
Assuming thickness t = 8mm
ro = outside knuclde radius = ri + t
= m2144.008.2136.
Ro = Outside crown radius = r1 +1 = 3.576 + .008
= 3.584 m
ho = outside height of domed head
200
2
D
R
2
D
RR o
o
o
oo (From geometry)
= 0.636 m
901.
584.34
576.3
4
22
oR
Do
685.
2
2144.*576.3
2
00
rD
hE = effective height of head = minimum of
2
rD
R4/D
h
oo
o
2
o
o
hE = .636 m
C = shape factor determined by graph
174.
576.3
636.
o
E
D
h
174.
576.3
008.
oD
t
from graph C = 1.40
Jf2
DP
t o
fall 300
C = 165 106
J = 1.0
77. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 77
Design Pressure 25
/103786.105.1 mNP
25
/1044753.1 mN
0.1101652
4.156.3.1044753.1
6
5
t
= 2.186 mm
Minimum wall thickness including corrosion allowance (3mm)
ts = 5 mm
ro = outside kunckle radius = .2186 m
Ro = outside crown radius = .3581 m
* Since the diameter of the absorber is less, therefore we join head by welding to the
shell, there is no need of flange arrangement we can use double-welded lap joint for
this.
NOZZLE DESIGN
Moler flow rate = 2 mole/sec (approx)
Density of Water = 990 K/m3
So, Voumetric Flow Rate = Flow Rate of formaldehyde * molar flow rate of
water* mol. Wt. *density
= 14.265 * 2 *18 *990/1000
= 508.40 Kg/sec
dopt = 282 * G0.52
* ρ-0.37
= 282 * 508.40.52
* 990-0.37
= 318 mm
Taking nozzle dia. = 320 mm or 32 cm
Similarly Nozzle Dia for gas comes out to be 48 cm
Nozzle Reinforcement Design
Nozzle is provided on the head and it is welded there internal design pressure
= 3.2071 105
N/m2
= 2
4
5
/10/
10
102071.3
cmkg
= 3.2071 kg/cm2
78. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 78
thickness of nozzle =
2071.3113002
35602071.3
2
mm
PJf
PDi
tn
= 4.39 mm
No corrosion allowance, since the material is stainless stell.
Actual thickness = 5 mm
Area to be compensated = d tRS
trs = thickness cale for shell
d = 5 cm (internal dia) + 8.4 10-3
(thickness) = 5 cm
= d tRS = 320 5
= 1600 mm2
Area available for compensation As = d ctt rss (of shell)
= 3104.85320 3
= 640 mm2
Area available for compensation (external branch)
CttH2A rnn1o
let height of nozzle = 5 cm
tn = thickness of nozzle = 5 cm
trn = thickness of nozzle calculated
C = corrosion allowance
Ao = 2 320 2
320001068.5 mm
Area available for compensation from internal branch = 0
because the nozzle does not project inside the vessel.
2
38406403200 mmAA so
Area to be compensated = 1600 mm2
=A
Since Ao + AS > A
This is satisfactory and no external compensation is required.
Reference Book
Support Design : Process Equipment Design (second editor) By M. V. Joshi
Since on absorber is not large, as result we can safely chose bracket or lug support for
vertical cylindrical vessels.
79. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 79
Data : -
Diameter of vessel =3.56 m
Height of vessel = 10.62 m
Clearance from vessel both of foundation = 1.5m
Weight of vessel
Weight of vessel = weight of absorber + weight of pacing
weight of absorber = s
2
i
2
o HDD
4
750062.1056.3.576.3
4
22
= 7142.5 Kg
from Page 23-35 John H. Perry.
for Stainless steel 201 .inCu/lb28.s
ftCu
bl
1228. 3
ftCu
bl
84.483
3
m/kg84.483018.16
3
/14.7500 mkg
Mass of packing = b
2
i HD
4
2
kg60962.756.3
4
2
= 4532 kg.
Total weight of Tower
with contents = 7142.5 + 4532 + 500 Kg extra
= 12174.5 Kg
wind pressure = 128.5 kg/m2
Skirt
Stress due to dead weight
80. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 80
ktkD
f
s0
w
0
w dead wt. of vessel contents and attachments
D0k = Outside diameter of skirt
tsk = thickness of skirt
2
0 /
885.10
3560
5.12174
cmkg
ktkt
f
ss
Stress due to wind load
ktkD
Mw4
fwb
s
2
0
Z
H
PlwM (for H 20m)
011lw DhkpP up to 20m height
P1 = wind pressure for lower part of vessel
k1
= coefficient depending on the shape factor (0.7 for cylindrical surface)
D0 = outside diameter of vessel
2
H
Dhkpm 011
ktkD
2/HDhkp.4
f
s
2
0
011
wb
kt
f
s
wb 2
356
100
2
62.10
56.362.105.1287.04
2
/
14.18
cmkg
kts
Stress due to seismic load
kt.Rok
WC
3
2
fsb
s
2
C = seismic coefficient = .08
W = total weight of vessel
Rok = outside radius of skirt
81. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 81
tsk = Skirt thickness
kt
bf
s
s 2
2
356
5.1217408.3/2
2
/
03813.
cmkg
kts
Maximum tensile stress at bottom of skirt
bfbforbfmaxf aswmaxt
2
/
255.7885.1014.18
cmkg
ktktkt sss
Permissible tensile stress = 1400 kg /cm2
cmcmkts 005282.
1400
255.7
.
=
05282 mm
Maximum compressive stress on skirt from equation
absbwb fforfmax
ktkttsk ss /025.29/14.18/885.10
intpoyield
3
1
lepermisssibfs
2
/666
3
2000
cmkg
cmcmkts 0721.0
666
025.29
Use a minimum thickness of 6 mm.
Skirt bearing plate
82. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 82
Assuming bolt circle diameter = Skirt diameter + 10 % of skirt dia in cm
=356 + 35.6 cm = 391.6 cm
= 3.916 m
Compressive stress between bearing plate and concrete foundation
Z
M
A
f ww
c
w = weight of vessel, contents & attachment
A = area of contact between bearing plate & foundation
Mw = bending moment due to wind
Z = Section modulus of area’
011e DhpkP
2
H
Dhpk
2
H
pM 011lww
22
3566.391
45.12174
fc
6.39132
3566.391
62.1056.35.1287.0
44
= 0.582 + .001 = 0.583 kg/cm2
which is less than the permissible value for concrete.
Maximum bending moment in bearing plate
2
bl
fM
2
cmax
l = difference between outer radius of bearing plate and outer radii of skirt
b = circumferential length
b
b
M
98.92
2
86.17583.0
max
2
Stress : 22
max
.
98.9266
BB tb
b
tb
M
f
2
2
/
8.557
cmkg
tB
83. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 83
Permissible stress in bending is 1575 kg/cm2
222
3541.0
1575
8.557
cmEmtB
cmtB 59. = 5.9 mm
Since the calculated thickness is less than 12 mm steel rolled angle may be used as a bearing
plate. Bolting chair need not be used.
84. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 84
EFFLUENT TREATMENT
WASTE CHARACTERSTICS
The major waste stream from the process is the "formaldehyde in water" and
formaldehyde vapors released into atmosphere. Beside formic acid, Carbon-mono-oxide
etc., which need to be treated before disposal. Carbon-mono-oxide and other gases are
in low concentration, so they are not treated as such but released at high elevation in
atmosphere.
Formalin is a highly toxic gas, and strict precautions are necessary to minimize risk
to workers and possible released during its handling. Major sources of fugitive air
emissions of chlorine and hydrogen are vents, seals, and transfer operations. Acid
and caustic wastewaters are generated in both the process and the materials
recovery stages.
Scrubber systems should be installed to control gas effluent emissions from condensers
and at storage and transfer points for liquid chlorine. Sulfuric acid used for drying
chlorine should be neutralized before discharge.
KEY ISSUES
The following summarizes the key production and control practices that will lead to
compliance with emissions guidelines.
1) Give preference to the effluent gases.
2) Adopt the following pollution prevention measures to minimize emissions.
3) Use scrubbers at the absorber to minimize the off-gases from it.
4) Recycling of water in air washer should be treated.
5) Recycling of dust containing water should be from suitable pumps.
In the effluent treatment plant, the formic acid going along with the water is passed
through an ion exchange bed. A sample design fo a deionizer for the treatment of formic
acid from the formalin stream is given below. A similar treatment can be devised for
outlet water stream.
85. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 85
Secondly, the settling tank can be designed for the treatment of rundown water from the
air washer.
DEIONIZER
Process design consideration
For ion exchange system sizing, the quantity of liquid to be processed in a period
of time must be determined. The processing rate if often expressed in gallons per
day or pounds per day.
Processing rate = quantity to be processed / time period minus regeneration time
Equipment must be sized such that the service time is sufficient to allow a unit in
regeneration to be completed prior to the exhaustion of the usable capacity of the
unit in service. The service time of a single unit in a multiple unit system is usually
designed for a service time, which exceeds the sum of the regeneration time
required for all of all the units in service. Having the required feed processing rate
per fixed-bed ion exchanger and the required length of the service period, the
exchanger or adsorption load to each unit for a service period can be calculated.
For continuous ion exchange equipment, the load is calculated on the basis of
exchange load per unit time. Generally, the capacities of an ion-exchange material
to remove a given component are determined experimentally. But the data is
available on common materials.
Variables on which the amount of ion-exchange bed required depends are
conc. of the component to be removed, process flow contact rate, regenerant
chemical conc., etc. Ion-exchange capacities are affected by the rate of mass
transfer between the process fluid and ion-exchange resin.
86. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 86
REQUIREMENT FOR EQUIPMENT DESIGN
TANKS AND VESSELS
Typically, a tank diameter which will allow service operation at flows that will
exceed 2 gpm/ft2
of tank area and not exceed 12 gpm/ft2
are acceptable. Once
the vessel diameter is determined, the ion-exchange media bed depth can be
calculated (media volume divided by area = bed depth). The resin bed depth in a
fixed-bed-ion-exchange unit usually should exceed 30in. and be limited to a
maximum depth of 96 in.. High flows per unit area and deep ion-exchange resin
depths may result in high-pressure drops. Pressure losses across a resin bed are
normally limited to 10-20 lb/in2
. Large pressure losses can, in combination with
exchange media volume changes (result from ionic or osmotic changes), causes
physical damage to the exchange media, the exchanger, and the internals of the
exchanger.
The chemicals that are used to regenerate the resins or the nature of the liquid
being processed dictate the use of interior coating or linings in an ion-exchanger
tank.
PIPINGS AND VALVES
These equipments are commonly constructed with PVC, stainless steel, or lined
carbon steel flanged piping. Selection of valves suitable for the intended service is
especially important. Lined carbon-steel pipes are generally used on large
equipments.
EXCHANGE MEDIA SUPPORT
Several design, like flat false bottom designs, dished tank bottom with graded
gravel media support beds, are available for supporting the ion-exchange resin.
FLOW DISTRIBUTION
For efficient working of ion-exchange resins, plug flow is generally preferred. Well-
distributed liquid flow distributors are required for that.
87. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 87
DESIGN
Formalin flow rate = 300 tons/day
Conc. of formic acid (max. possible) = 0.04%
Formic acid (in Kg/day) = (0.04/100) * 300 *1000
= 120 Kg/day
Reaction occuring is:
R(OH)2 + 2HCOOH R(COOH)2 + 2H2O
Density of 37 wt.% formaldehyde solution:
d= 1.000 + 0.003*W
d= 1.000 + 0.003*37
d= 1.111
d= 1111 Kg/m3
Volume of solution = weight/density
Volume of solution = 300*1000/1111
volume of solution = 270.03 m3
/day
conc. of formaldehyde = 120Kg/day
270.03 m3
/day
= 0.444 gm/lt
= 444 mg/lt
Eq. Wt. Of HCOOH =46/1(mol.wt./bascity)
=46
meq/lt of HCOOH = 444 mg/lt / 46
= 9.65
Total meq treated per day = 9.65 * 270.03 * 103
= 2605.79 eq/day
Resin Requirement:
Assumed 6-day operation cycle for the specific resin
Treating power of resin = 70 eq/ft3
88. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 88
Resin reqd. =2605.79 eq./day* 6
day/cycle
70 eq./ft3
= 223.35ft3
of
resin/day
Choosing column diameter = 3 ft. = 0.0762 m
Cross-section area = 3.142*32
/4 = 7.07 ft2
Depth = volume/cross-sectional area
= 223.35/7.07 = 31.6 ft = 9.48 m
50% of free space is kept for bed expansion for backwashing and cleaning.
So, the height of reqd. column is 1.5 * 9.48 =14.22 m
Height is quite high. So, using 2 columns of 7.11 m height each.
Each containing =9.48/2 = 4.74 m
Free space = 7.11 – 4.74= 2.37 m
Regenrant Reqd.
Regenrant used is 10% solution of NaOH
Regenrant requirement is 4.7 lb of NaOH/ ft3
of resin
So NaOH reqd. = 4.7 lb/ft3
*223.35 ft3
/cycle
= 1049.745 lb/cycle = 476.58 Kg/cycle
Requirement of 10% solution
= 476.58*100/10
= 4765.8 Kg/cycle
Water requirement
Water requirement =100 gallon/ft3
of resin
Water requirement = 100gallon/ft3
of resin* 223.35 ft3
/cycle
= 22335 gallon/cycle
= 84.55 m3
/day
89. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 89
SAFETY POLICY
EFFECITVE SAFETY AND LOSS PREVENTION IS ESSENTIAL FOR A COMPANY’S
PROSPERITY
Hazards in the chemical industry are much more than in any other industry.
Besides mechanical and electrical hazards, chances of fire explosion, inhalation
of toxic gases, handling of corrosive and poisonous substances are encouraged in
chemical industry. Thus it is important that the employee should recognize safety
and fire hazards in the manufacture of soda ash.
Objectives of industrial safety program are: -
a) To lessen human sufferings.
b) To prevent damage to plant and machinery.
c) To reduce the amount of time lost due to accidents.
d) To hold the expense of workman compensation to minimum.
GENERAL SAFETY
1) Alternate means of escape should be provided in the plant area.
2) Gloves and goggles should be used while sampling or welding the
equipment.
3) Going without helmet, gloves and rubber bolts near the leaking
equipment should be avoided.
ELECTRICAL HAZARDS:
Accidents attributed to electrical hazards are:-
1) Shocks by A.C. and burns by D.C. due to poor indication and protection
from high voltage.
2) Faulty and poor wiring.
3) Static electricity discharges.
90. Formaldehyde 2014
B.TECH Project – IIT (BHU) Varanasi Page 90
4) Fires from sparking near inflammable material.
PROCESS UTILITIES
Process utilities are a major necessity for any chemical plant. The following are
usually considered utilities although in some companies one or more are treated
under other categories on the cost sheet. The utility cost for the whole plant (from
coat estimation sheet) is Rs.1.97412×108
Steam, Cooling water, Deionized water, Electric power, Refrigeration ,
Compressed air , Instrument air, Effluent treatment. Their effect on the cost of
the production will naturally depend on the process involved Occasionally the
costing of the utilities will be intricate because utilities require other utilities for
their own manufacture.
STEAM
A steam generation unit should be present which is a source of steam where ever
it is required .It is measured in thousands of pounds or for small boilers it may be
measured in boiler horse power(33,749 BTU/hr).A pound of steam generated may
have 1200 to1600BTU/lb.Most plants use several stem pressure levels . In many
plants waste heat boilers are additional source of steam at intermediate pressure
levels .
Steam is available at following rating in our plant
Pressure ----------- 400 Kpa
Temperature-------- 204.44 o
C
Latent heat -------------826 Btu/lb or 1920 Kj/kg
WATER
Water requirements fall under three categories, cooling, process, and
miscellaneous such as washing or drinking. For cooling purpose it is usually
uneconomical and occasionally violation of conservation laws to use to use a